Manual Generador SR4 B SENR5359-05

SENR5359-05
April 2002
Systems Operation
Testing and Adjusting
Disassembly and
Assembly
SR4B Generator
i01658146
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
3
Table of Contents
Table of Contents
Systems Operation Section
General Information ................................................ 4
Component Descriptions ........................................ 5
Generator Operation ............................................. 12
Lead Connections ................................................. 20
Glossary ............................................................... 24
Testing and Adjusting Section

Testing and Adjusting
General Information .............................................. 28
Service Tools ........................................................ 28
Troubleshooting .................................................... 29
Generator Set - Test ............................................. 30
Varistor - Test ........................................................ 32
Rotating Rectifier - Test ........................................ 32
Winding - Test ....................................................... 35
Insulation - Test ..................................................... 36
Resistor - Test ....................................................... 38
Generator - Dry ..................................................... 38
Leads - Connect ................................................... 40
Exciter Field - Flash .............................................. 41
Disassembly and Assembly Section

Exciter - Remove and Install ................................. 44
Generator - Remove ............................................ 49
Generator - Install ................................................ 53
Generator - Align .................................................. 62
Rotor - Remove and Install ................................... 64
Bearing - Remove and Install ............................... 68
Coupling - Remove ............................................... 71
Coupling - Install ................................................... 71
Index Section
Index ..................................................................... 73
4

i01152388
General Information
SMCS Code: 4450
g00609958
Illustration 3
SR4B Generator
(1) Generator terminal strip
(2) Main armature (stator)
(3) Main field (rotor)
(4) Rotor shaft
(5) Permanent magnet pilot exciter (PMPE)
(6) Exciter
g00611770 (7) Bearing
Illustration 1 (8) Fan
Generator Set
The SR4B generator has the following
characteristics:
• three-phase alternating current

• brushless type
• four pole or six pole design
Stationary main armature (2) bolts to the engine
flywheel housing. A flexible plate type coupling
connects rotor shaft (4) to the engine flywheel.
Rotating main field (3) is keyed directly to the rotor
shaft.
The SR4B generator is a self-ventilated generator.

Air enters the generator through screened orifices
that are located at the rear of the generator. Air exits
the generator through screened orifices that are
located at the drive coupling end of the generator.
Fan (8) attaches to rotor shaft (4). Bearing (7)
Illustration 2 g00611772 supports the exciter end of the rotor shaft.
Generator Set
Note: Some larger generators have two bearings. In
this case, there will be a bearing at each end of
the generator shaft.
5
i01152505
Component Descriptions
SMCS Code: 4450
All SR4B generators have the same basic design.

The following list displays some differences that
may occur between SR4B generators:
• Power for the exciter field is provided by either

the permanent magnet pilot excited (PMPE)
method or the self-excited (SE) method.
• The location of the bearing can be inboard or

outboard. The following factors determine the
location of the bearing: vibration characteristics
of the engine, vibration characteristics of the
generator, the size of the engine, and the size of
the generator.
• On PMPE generators, the pilot exciter can be

inboard or the pilot exciter can be outboard.
Note: Some larger generators have two bearings.

When a generator has two bearings, there is a
bearing at each end of the generator shaft.
g00611832
Illustration 4
PMPE Type Components
(1) Rectifiers (5) Exciter field (stator) (8) Main field (rotor)
(2) Pilot exciter field (permanent magnet) (6) Bearing with a sleeve for 3500 Engine (9) Rotor shaft
(3) Pilot exciter armature (PM armature) Family only (10) Fan
(4) Exciter armature (rotor) (7) Main armature (stator)
6
g00611839
Illustration 5
PMPE Type Components with a Pilot Exciter
(1) Rectifiers (6) Bearing
(2) Exciter field (stator) (7) Main armature (stator)
(3) Exciter armature (rotor) (8) Main field (rotor)
(4) Pilot exciter armature (PM armature) (9) Rotor shaft
(5) Pilot exciter field (permanent magnet) (10) Fan
7
g00611845
Illustration 6
SE Type Components with Inboard Bearing
(1) Rectifiers (5) Main armature (stator)
(2) Exciter field (stator) (6) Main field (rotor)
(3) Exciter armature (rotor) (7) Rotor shaft
(4) Bearing (8) Fan
8
g00611851
Illustration 7
SE Type Components (Outboard Bearing)
(1) Bearing (5) Main field (rotor)
(3) Exciter field (stator) (7) Rotor shaft
(4) Rectifiers (8) Fan
9
g00611856
Illustration 8
Two-Bearing Generator (PMPE Type Components)
(1) Rectifiers (5) Exciter field (stator) (8) Main field (rotor)
(2) Pilot exciter field (permanent magnet) (6) Bearing with a sleeve for 3500 Engine (9) Rotor shaft
(3) Pilot exciter armature (PM armature) Family only (10) Fan
g00626058
Illustration 9
SR4B generator that is used with a 3406E engine
(1) Rectifiers (5) Main armature (stator)
(2) Exciter armature (rotor) (6) Main field (rotor)
(3) Exciter field (stator) (7) Fan
(4) Bearing (8) Rotor shaft
10
Rotating Field Assembly (RFA)
g00611866
Illustration 11
RFA Components (PMPE Type)
(1) Pilot exciter field (permanent magnet)
(2) Exciter armature (rotor)
(3) Bearing
(4) Main field (rotor)
(5) Rotor shaft
(6) Rectifiers
The RFA components attach to rotor shaft (5), which

is supported by the engine flywheel and bearing (3).
g00609975
Illustration 10
PMPE Generator Wiring Diagram
(CR1 - CR6) Diodes
(CR7) Varistor
(L1) Exciter field (stator)
(L2) Exciter armature (rotor)
(L3) Main field (rotor)
(L4) Main armature (stator) g00611892
(L5) Pilot exciter armature Illustration 12
(PM) Permanent magnet Main Armature (Stator (L4))
(R5) Resistor
(RFA) Rotating field assembly
(TR1) Optional Voltage droop transformer
The generator main armature is stationary and
(T0, T1, T2, T3, T7, T8, T9) Generator Terminals and/or Generator the generator main armature contains the stator
leads windings.
11
Main Field (Rotor) Pilot Exciter
g00611914 g00611961
Illustration 13 Illustration 16
Rotating Field Assembly (RFA) Pilot Exciter
(1) Main Field (Rotor (L3))
The pilot exciter is used on PMPE generators.
Generator Main Field (1) is part of the rotating field The pilot exciter consists of stationary pilot exciter
assembly. The generator main field rotates with the armature (1) and the rotating pilot exciter field (2).
rotating field assembly. The pilot exciter field is also referred to as the
permanent magnet (PM).
Exciter Rotating Rectifier Blocks
g00611951
Illustration 14
Exciter Armature (Rotor (L2))
g00610186
Illustration 17
Two Diode Rectifier Block
g00611956
Illustration 15
Exciter Field (Stator (L1))
12
i01149466
Generator Operation
SMCS Code: 4450
g00610236
Illustration 18
Three Diode Rectifier Block
(1) Positive rectifier block
(2) Negative rectifier block
g00609958
Illustration 20
SR4B Generator
(1) Generator terminal strip
(2) Main armature (Stator)
(3) Main field (Rotor)
(4) Rotor shaft
(5) Permanent magnet pilot exciter
(6) Exciter
(7) Bearing
(8) Fan
An engine supplies the power in order to turn rotor

shaft (4). The armature of exciter (6) and main
field (3) attach to the rotor shaft. As the rotor shaft
turns, the exciter generates AC current. The rectifier
Illustration 19 g00611973 components convert the AC exciter current to DC
current. This DC current is supplied to the main
The rotating rectifier blocks are part of the rotating field. A magnetic field is created around the poles
field assembly (RFA). There are three types of of the main field. As the main field turns with the
rotating rectifier blocks that are used. The size of rotor shaft, the magnetic field also rotates. The
the generator determines the size of the rotating magnetic field induces an AC voltage into stationary
rectifier block that is used. main armature (2). The main armature is a coil with
many turns of wire. The current that flows through
• The two diode rectifier block contains two diodes. the main armature flows to the load.
Three identical blocks are required.
Two rectifiers supply DC current to main field (3).
• The three diode rectifier block contains three The load voltage is controlled by varying the current
diodes. Two different blocks are required. One that goes to the exciter’s armature. There are two
block is positive and the other block is negative. methods for excitation that are used on SR4B
Generators:
• The six diode rectifier block contains six diodes.
One block is required. • Permanent magnet pilot excited (PMPE)
Note: For additional information, refer to Generator • Self-excited (SE)
Operation, “Rectifier Circuits”.
13
Permanent Magnet Pilot Excited Permanent magnet pilot excited generators receive
power for the voltage regulator from a pilot exciter.
(PMPE) Generator Self-excited generators receive power for the
voltage regulator from the main armature. The
pilot exciter consists of permanent magnet (PM)
and Pilot Exciter Armature (L5). The pilot exciter
operates independently from the generator output
voltage. Constant excitation during a large load
application is possible. Constant excitation is
possible because the irregularities that occur in the
generator output voltage are not fed back into the
exciter. The irregularities that occur in the generator
output voltage are caused by load conditions. The
independent operation also allows the generator to
sustain excessive currents for short periods of time.
When the engine starts turning the Rotating Field

Assembly (RFA), the permanent magnet (PM)
induces an AC voltage in the pilot exciter armature
(L5). The pilot exciter armature has three coils
of wire. The pilot exciter armature generates
three-phase alternating current (AC). The resulting
AC flows through wires “11”, “12”, and “13” to the
voltage regulator. Within the voltage regulator, the
three-phase alternating current is rectified to direct
current (DC). A controlled amount of DC is fed to
exciter field (L1) through terminals “F1” and “F2”.
Direct current now flows to exciter field (L1) which

creates a magnetic field. Exciter armature (L2)
rotates in this magnetic field. The exciter field
and the exciter armature generate three-phase
alternating current. The AC is then rectified by a
three-phase full-wave bridge rectifier circuit. This
rectifier circuit is made of the following diodes: CR1,
CR2, CR3, CR4, CR5, and CR6.
g00609975 The DC output from the bridge rectifier is carried
Illustration 21
PMPE Generator Wiring Diagram to main field (L3) by conductors which are routed
through a passage in the generator shaft. Current
(CR1 - CR6) Diodes
(CR7) Varistor through the main field creates the magnetic field of
(L1) Exciter field (stator) the generator. As the main field rotates, the main
(L2) Exciter armature (rotor) field induces a three-phase AC voltage in main
(L3) Main field (rotor) armature (L4). This voltage is sent to the following
(L4) Main armature (stator)
(L5) Pilot exciter armature
terminals: T0, T1, T2, and T3. These terminals are
(PM) Permanent magnet connections for the load.
(R5) Resistor
(RFA) Rotating field assembly To keep the output voltage constant with changing
(TR1) Optional Voltage droop transformer loads, it is necessary to control the exciter current.
(T0, T1, T2, T3, T7, T8, T9) Generator terminals and/or Generator
leads This control is the function of the voltage regulator.
The voltage regulator senses the generator output
voltage at the following wires: “20”, “22”, and “24”.
The regulator sends current to the exciter through
wires “F1” and “F2”. The amount of current is
dependent on the sensed voltage. The current is
drawn from the pilot exciter and the armature (wires
“11”, “12”, and “13”). Regardless of the generator’s
type (PMPE generator or self-excited generator),
changing the exciter current has the same effect on
the generator’s operation. See the topic Self-Excited
Generators for a description of generator operation
when the exciter current changes.
14
Note: For more information on voltage regulation, Self-excited generators receive the power for
see the appropriate voltage regulator service excitation from the generator armature (the
manual. generator output). When the engine starts turning
the Rotating Field Assembly (RFA), the residual
PMPE generators provide the magnetism for magnetism in exciter field (L1) causes a small
start-up of the generator. A Permanent Magnet amount of AC voltage to be generated in exciter
(PM) supplies the initial magnetism that is required armature (L2). Induced voltage causes current to
at start-up. Flashing the field is not required for flow. This current is present in the exciter armature.
start-up of the generator. The AC is then rectified by a three-phase full-wave
bridge rectifier circuit. This rectifier circuit is made
of the following diodes: CR1, CR2, CR3, CR4, CR5,
Self-Excited (SE) Generators and CR6. Direct current then flows through main
field (L3). The flow of DC through the main field
creates a magnetic field. This magnetic field adds
to the existing residual magnetism of the main
field. As the main field rotates, an AC voltage is
induced into main armature (L4) which appears as
a three-phase AC voltage at the following output
terminals: T0, T1, T2, and T3. The voltage regulator
taps the AC output through wires: “20”, “22”, and
“24”. During start-up, this tapped output is sensed
by the voltage regulator. The voltage regulator
senses the output as a low-voltage output condition.
Therefore, the voltage regulator output to the exciter
field is increased so that the generator output will
continue to increase up to the rated voltage.
The amount of current which flows through the

exciter directly affects the generator output
voltage. The voltage regulator maintains a constant
generator output voltage with changing loads. The
voltage regulator controls the DC voltage and the
DC current. The DC voltage and the DC current
is supplied to the exciter which produces the
generator output voltage. The voltage regulator
senses the generator’s output voltage at wires:
“20”, “22”, and “24”. The voltage regulator then
supplies a controlled DC voltage and DC current to
the exciter through wires “F1” and “F2”.
Note: For more information on voltage regulation,

see Service Manual, “Voltage Regulator”.
g00610159
Illustration 22
SE Generator Wiring Diagram
(CR1 - CR6) Diodes
(CR7) Varistor
(TR1) Optional Voltage droop transformer
leads
Self-excited generators are an option. The standard

generator is a PMPE generator.
15
When the voltage regulator senses a decrease in Rectifier Circuits

output voltage, the voltage regulator will increase
the DC voltage and the DC current. This DC voltage
and DC current is sent through the exciter through
wires “F1” and “F2”. The exciter field’s magnetic
field increases. As the magnetic field in the exciter
field is increased, the AC voltage that is induced in
the exciter armature is increased. This increased AC
voltage from exciter armature (L2) causes more AC
current to flow. The AC current is then rectified by
a three-phase full-wave bridge rectifier circuit. This
rectifier circuit is made of the following diodes: CR1,
CR2, CR3, CR4, CR5, and CR6. The increased DC
output from the bridge rectifier is carried to main
field coils (L3) by conductors. These conductors are
routed through a passage in the generator shaft.
Increased current through main field coils increases
the magnetic field of the generator. The increased
magnetic field induces a larger AC voltage into
main armature (L4). The three-phase AC voltage
increases until the voltage regulator no longer
senses a decreased output voltage.
g00610163
Illustration 23
When the voltage regulator senses an increase in
Rectifier Circuit
output voltage, the voltage regulator will decrease
the DC voltage to the exciter. This will result in a (CR1 - CR6) Diodes
(CR7) Varistor
decrease in generator output voltage. (L2) Exciter armature (rotor)
Residual magnetism is necessary for start-up of (R5) Resistor
the self-excited generator. The main field coils are
wound on magnetic steel which retains a small The following diodes form a bridge rectifier circuit:
amount of magnetism after shutdown. After time CR1, CR2, CR3, CR4, CR5, and CR6. The bridge
and certain conditions, the residual magnetism rectifier circuit receives three-phase alternating
may decrease. The residual magnetism will then current from exciter armature (L2). The bridge
be insufficient to start the generating process. If rectifier circuit rectifies the alternating current into
this occurs, refer to Testing And Adjusting Section, direct current. The DC power is then routed to main
“Exciter Field - Flash”. field (L3).
Diodes “CR1” through “CR6” are contained in

rotating rectifier blocks. Three different rotating
rectifier blocks are currently used on SR4B
generators. The type of the generator and the size
of the generator determine the rotating rectifier
block that is used.
There are three types of rotating rectifier blocks:
Two-diode rectifier block – The two-diode rectifier

block contains two diodes. Three identical blocks
are required.
Three-diode rectifier block – The three-diode rectifier

block contains three diodes. Two different blocks
are required. One block is positive and the other
block is negative.
Six-diode rectifier block – The six-diode rectifier

block contains six diodes. One block is required.
16
Rectifying the current creates heat. The rotating

rectifier blocks are fastened to heat sinks. These
heat sinks spread the heat. These heat sinks also
allow the rotating rectifier blocks to operate at a
cooler temperature.
Two-Diode Rectifier Block
g00610202
Illustration 26
g00610186
Illustration 24
The wiring of the three two-diode rectifier blocks
Two-diode rectifier block
(1) “L2” (wire passage)
(2) Heat sink assembly
(3) Three two-diode rectifier blocks
(4) “L3” (wire passage)
(5) R5
(6) CR7
Three identical two-diode rectifier blocks (3) are

interconnected in order to form a bridge rectifier
circuit. Each of the two-diode rectifier blocks
contains one of the following sets of two diodes:
• “CR1” and “CR4”

Two-diode rectifier blocks must be wired correctly.
Refer to Illustration 26. Each “AC” terminal connects
to an exciter armature wire (1). The “+” terminals
connect together. The “+” terminals also connect to
g00610197
one “L3” wire (4) of the main field. The “-” terminals
Illustration 25 connect together. The “-” terminals also connect to
The locations of the three two-diode rectifier blocks the other “L3” wire (4) of the main field.
17
The two-diode rectifier blocks (3) are mounted to

the heat sink assembly (2). The heat sink assembly
is on the end of the generator shaft. Heat sink
assembly (2) also contains a varistor (6) and a
resistor (5). The varistor and the resistor are used
to protect the generator circuit. Refer to Generator
Operation, “Generator Circuit Protection”.
Three-Diode Rectifier Block
g00610241
Illustration 29
The wiring of the three-diode rectifier blocks
g00610236 (1) Positive rectifier block
Illustration 27
(2) Negative rectifier block
Three-diode rectifier blocks (3) “L3” (two-wire passage)
(1) Positive rectifier block (4) Heat sink assembly
(2) Negative rectifier block (5) R5
(6) “L2” (three-wire passage)
(7) CR7
In order to form a bridge rectifier circuit, two similar

three-diode rectifier blocks are connected. Each
of the three-diode rectifier blocks contain three
diodes. Positive rectifier block (1) contains diodes
“CR1”, “CR2”, and “CR3”. Negative rectifier block
(2) contains diodes “CR4”, “CR5”, and “CR6”.
Three-diode rectifier blocks must be wired correctly.

Refer to Illustration 29. Each “AC” terminal connects
to an “L2” wire from the exciter armature (6). The “+”
terminals connect together. The “+” terminals also
connect to one “L3” wire (3) of the main field. The
“-” terminals connect together. The “-” terminals also
connect to the other “L3” wire (3) of the main field.
The positive rectifier block (1) and the negative

rectifier block (2) are mounted to heat sink assembly
(4). The heat sink assembly is on the end of
the generator shaft. Heat sink assembly (4) also
g00610240 contains a varistor (7) and resistor (5). The varistor
Illustration 28
The location of the two three-diode rectifier blocks and the resistor are used to protect the generator
circuit. Refer to Generator Operation, “Generator
Circuit Protection”.
18
Six-Diode Rectifier Block
g00610335
Illustration 32
g00610322
Illustration 30 Six-Diode Rectifier Block Location (Outboard Bearing)
Six-Diode Rectifier Block (1) Exciter
(2) Six-Diode Rectifier Block
(3) Disc
(4) Main Field
The six-diode rectifier block contains the six diodes

of the bridge rectifier circuit. Each “AC” terminal
connects to an exciter armature wire. The “+”
terminal and the “-” terminal connect to main field
(4).
On inboard bearing type generators, the six-diode

rectifier block is on the end of the generator shaft.
On outboard bearing type generators, six-diode
rectifier block (2) is mounted on disc (3). Disc (3) is
between exciter (1) and main field (4).
g00610330
Illustration 31
Six-Diode Rectifier Block Location (Inboard Bearing) The six -diode rectifier block also contains varistor
(CR7) which is used to protect the generator circuit.
Refer to Generator Operation, “Generator Circuit
Protection”.
19
Generator Circuit Protection
g00610379
Illustration 34
Varistor (CR7)
Varistor (CR7) protects the following diodes

by suppressing any abnormal transient peak
voltages: CR1, CR2, CR3, CR4, CR5, and CR6. On
generators that use the two-diode rectifier blocks
or the three-diode rectifier blocks, varistor (CR7)
is a separate component and mounts on the heat
sink assembly. On generators that use the six-diode
rectifier block, varistor (CR7) is contained within the
six-diode rectifier block.
Note: Some generators are provided with another

g00609975 varistor (CR8) for additional protection.
Illustration 33
(CR1 - CR6) Diodes
Resistor (R5) is a separate component and mounts
(CR7) Varistor on the heat sink assembly. This resistor is only used
(L1) Exciter field (stator) on some of the larger generators. Resistor (R5)
(L2) Exciter armature (rotor) provides a low resistance circuit from the insulated
(L3) Main field (rotor) windings to the shaft and cores of revolving field
(L5) Pilot exciter armature assembly (RFA). Resistor (R5) is a 27000 ohm
(PM) Permanent magnet resistor. Air friction on the windings can cause an
(R5) Resistor electrostatic charge. If this resistor is not installed,
(RFA) Rotating field assembly these charges can cause voltages to become high
(TR1) Optional voltage droop transformer
enough to destroy the winding insulation. Resistor
leads (R5) allows charges to dissipate as the charges are
generated. This resistor also prevents any buildup
of voltage. Because of the resistance value and the
power rating of resistor (R5), a ground failure at
any point on revolving field assembly (RFA) will not
prevent the generator from operating normally. A
ground failure will not damage resistor (R5).
20
The voltage regulator and related components also

protect the generator. All voltage regulators have
fuses, which will stop the current flow to the exciter.
When no voltage is applied to the exciter, the
generator output voltage is reduced to a very low
level. These fuses open very rapidly. This protects
against secondary damage that is caused by
another component failure. If any fuse is replaced,
use only a fuse of the same type and amperage
rating. A larger amperage rating or a fuse which
does not open rapidly will not prevent damage to
other components.
All voltage regulators have excessive current

protection circuits that also open the excitation g00610396
circuit. Illustration 36
Space Heater Connection Diagram
Note: For more information on voltage regulation,
see the appropriate voltage regulator service The SR4B generator can operate in high humidity
manual. conditions without problems. However, problems
can occur when the generator is idle and the
surrounding air is warmer than the generator.
Space Heaters Moisture can form on the windings. This moisture
will result in poor performance or even damage to
the windings. Whenever the generator is not active,
the space heaters should be operated.
An external source is required to operate the space

heaters. This source can be either 115 VAC or 230
VAC. Both of these sources must be single-phase.
When the external source is 50 hertz, 200 VAC must
be used. Refer to Illustration 36.
i01152054
Lead Connections
SMCS Code: 4459
The Wye configurations and the Delta configurations

are the most common generator lead connections.
The following three-phase connection diagrams
illustrate the proper connection and lead
g00610386
identification for Wye configurations.
Illustration 35
Location of the Space Heater (Large Frame Generator)
The space heater for small frame generators is

located within the housing of the main stator. The
space heater is located in the generator’s exciter
end.
21
Four Lead Wye Connection Table 2

SIX LEAD WYE CONNECTIONS
Generator Lead Line Lead Regulator
Lead(1)
T1 T1 22
T2 T2 24
T3 T3 20
Connect T4, T5, Neutral -
and T6
(1) Regulator leads are used on Generator sets with a 3500B
Engine. On PMPE generators, sensing isolation transformers
are used. The line lead’s voltage connects to one side of the
sensing isolation transformer. The voltage regulator connects
to the other side of the sensing isolation transformer. On SE
generators, the stator windings are tapped in order to supply
sensing voltage to the regulator.
Ten Lead Wye Connection (High

Voltage)
g00611469
Illustration 37
Four Lead Wye Connection Diagram
Table 1
FOUR LEAD WYE CONNECTIONS
Generator Lead Line Lead Regulator Lead
T1 T1 22
T2 T2 24
T3 T3 20
T0 Neutral -
Six Lead Wye Connection
g00611584
Illustration 39
Ten Lead Wye Connection Diagram (High Voltage)
g00611486
Illustration 38
Six Lead Wye Connection Diagram
22
Table 3 Twelve Lead Wye Connection (High

TEN LEAD WYE CONNECTIONS (HIGH VOLTAGE) Voltage)
Generator Lead Line Lead Regulator Lead
T1 T1 -
Connect T4 - 22
and T7
T2 T2 -
Connect T5 - 24
and T8
T3 T3 -
Connect T6, T9 - 20
T0 Neutral -
Ten Lead Wye Connection (Low

Voltage)
g00611603
Illustration 41
Twelve Lead Wye Connection Diagram (High Voltage)
Table 5
TWELVE LEAD WYE CONNECTIONS (HIGH
VOLTAGE)
Load
T1 T1 -
Connect T4 and T7 - 22
T2 T2 -
T3 T3 -
g00611596
Illustration 40 Connect T10, T11, Neutral -
Ten Lead Wye Connection Diagram (Low Voltage) and T12
Table 4
TEN LEAD WYE CONNECTIONS (LOW VOLTAGE)
Lead
Connect T1 and T7 T1 22
Connect T4, T5, Neutral -
T6, and T0
23
Twelve Lead Wye Connection (Low Six Lead Delta Connection

Voltage)
g00611618
Illustration 43
g00611608 Six Lead Delta Connection Diagram
Illustration 42
Twelve Lead Wye Connection Diagram (Low Voltage) Table 7
Table 6 SIX LEAD DELTA CONNECTIONS
TWELVE LEAD WYE CONNECTIONS (LOW VOLTAGE) Generator Lead Line Lead Regulator
Lead(1)
Lead Connect T1 T1 22
and T6
Connect T2 T2 24
Connect T2 and T8 T2 24 and T4
Connect T3 and T9 T3 20 Connect T3 T3 20
- and T5
Connect T4, T5, T6, T10, Neutral
T11, and T12 (1) Regulator leads are used on Generator sets with a 3500B
Engine. On PMPE generators, sensing isolation transformers
are used. The line lead’s voltage connects to one side of the
sensing isolation transformer. The voltage regulator connects
to the other side of the sensing isolation transformer. On SE
generators, the stator windings are tapped in order to supply
sensing voltage to the regulator.
24
Twelve Lead Delta Connection For more information, refer to Testing And Adjusting,
“Leads - Connect”.
Depending on the connections that are made

between the load and the generator line leads,
single-phase voltages and/or three-phase voltages
are possible. For more information, refer to
Operation and Maintenance Manual, LEKQ7119,
“Engine Data Sheet”. Refer to Connection Diagrams,
SENR4794.
i01731631
Glossary
SMCS Code: 4450
Actuate – Actuation relates to putting something

in motion.
Anode – An anode is the positive end of a diode or

an anode is the positive end of a rectifier.
g00611504
Illustration 44
Twelve Lead Delta Connection Diagram Blocking Rectifier – A blocking rectifier permits
direct current flow in only one direction.
Table 8
TWELVE LEAD DELTA CONNECTIONS
Bolted – A bolted device uses a bolt to hold two
or more parts together.
Lead Bridge – A bridge is a circuit that is used to
Connect T1 and T1 22 measure small quantities of current, voltage, or
T12 resistance.
Connect T4 and T7 - - Bridge Rectifier – A bridge rectifier is a circuit that
Connect T2 and T2 24 is used to change alternating current (AC) to direct
T10 current (DC).
Connect T5 and T8 - -
Buildup – A buildup is a gradual increase in voltage.
Connect T3 and T3 20
T11 Cathode – A cathode is the negative end of a diode
or a cathode is the negative end of a rectifier.
Connect T6 and T9 Neutral -
Capacitance – Capacitance is the ability to store
Generator line leads (“T1” through “T12”) can an electrical charge.
be multiple. For example, three generator line
leads might be designated as “T4”. Multiple line Capacitor – A capacitor is a device that will store
leads allow the lead to be flexible. Flexible leads an electrical charge.
help maintain the current carrying capacity which
is required. If generator line leads are similarly Circuit Breaker – A circuit breaker is an automatic
marked, these leads should be connected together. switch that is used to open a circuit.
These leads should be treated as one conductor.
Generator line leads can terminate in the following Circulating Current – Circulating current is the flow
ways: of current between two or more generators that are
working in parallel. Circulating current is also the
• end at the terminal strip flow of current between two or more generators that
are parallel with a utility line.
• directly fastened to the load leads
Conduct – Conducting relates to allowing the flow
• fastened to another component of current.
25
Continuity – Continuity provides a path for current Generate – This refers to the process of making
flow. electricity.
Control – A control is a device that controls another Grounded – A device is grounded by making a
device. A control is also a circuit that controls a connection to ground. A device could also be
device. grounded by making a connection to a component
that is connected to ground.
Direct Current (DC) – Direct current is current flow
that moves in only one direction in a given circuit. Humidity – Humidity is the water content that is
present in the air.
Damping – Damping refers to decreasing the
amplitude of a signal. Impedance – Impedance is the resistance to
alternating current.
De-energized – A de-energized input refers to
stopping the current that is going to a component. Impulse Modulation – Impulse modulation changes
the following characteristics of a wave: amplitude,
Distribution Winding – Distribution windings go from frequency, and phase. This is accomplished by
one end of the core to the other end of the core. impressing one wave on another wave that has
These windings are arranged in groups that are constant properties.
located in several slots.
Induce – This refers to the transfer of power from
Droop – Droop refers to a decrease. one device to another device. The transfer is done
via a magnetic field or via an electric field.
Excitation – Excitation is controlled direct current
(DC) that is used to make a magnetic field. Interference – Interference is an unwanted mixture
of electrical signals. Interference is usually
Energized – An energized input refers to activating associated with electrical noise.
a device.
Instrumentation – Instrumentation is a group of
Electrostatic Charge – Electrostatic charge is instruments that are used for measuring a system
electricity that is caused by induced voltage and function.
stored charge.
Insulated – An insulated device is a device that is
Exciter – An exciter supplies direct current (DC) to covered with a nonconductive material.
the field windings of the generator.
Lead – A lead is a wire.
Field – A field is a magnetic line of force that
surrounds a conductor. This force is caused by Line Voltage – Line voltage is the output voltage
current flow in the conductor. of the generator that is measured between the
generator leads (phases).
Field Windings – Field windings are many turns of
wire that are wrapped around an iron core. When Lock In – A lock in occurs when a contact closes in
direct current (DC) flows through the field windings, order to keep a device in an energized state.
a magnetic field is produced. This magnetic field is
comparable to the magnetic field of a bar magnet. Lock Out – Lockout occurs when a contact opens
in order to keep a device in a de-energized state.
Flashing – Flashing is a process of putting direct
current from an external source into the field Magnetic – A magnetic device is a device that has
windings. This process causes the generator to the characteristics of a magnet.
produce an output voltage.
Magnification – Magnification refers to the
Flux – Flux is magnetic lines of force. enlargement of an item.
Full-Wave Rectifier – A full-wave rectifier changes Module – A module is an assembly of electronic

the positive phase and the negative phase of components and electronic circuits.
alternating current to direct current.
Moisture – Moisture is the presence of water.
Gain – Gain relates to the relationship between
input magnitude and output magnitude. Oscillation – Oscillation is the flow of electricity that
periodically changes direction and/or magnitude.
Gate – A gate is an electronic part of a controlled
rectifier (thyristor).
26
Permanent Magnet (PM) – A permanent magnet SCR – An SCR is a silicon controlled rectifier. An
supplies the initial magnetism that is required to SCR is a semiconductor.
start a PMPE generator.
SE – An SE generator is a self-excited generator.
Permanent magnet pilot exciter (PMPE) – PMPE An SE generator uses a small part of the generator
generators receive power for the voltage regulator output to provide excitation current back to the
from a pilot exciter. A PMPE generator consists of a generator. An SE generator uses residual magnetic
permanent magnet and a pilot exciter. field for start-up.
Phase Winding – A phase winding is a group of Semiconductor – A semiconductor is a component

generator stator coils. Electric power for one phase such as one of the following components:a
of the load is induced in the phase winding. transistor, a diode, and a thyristor. Semiconductors
have electrical characteristics that are between a
Polarity – Polarity is the positive characteristics or conductor and insulation.
the negative characteristics of two poles.
Series Boost – A series boost is an attachment that
Pulsating – Pulsating relates to the characteristics allows generator output to continue for a short time
of current that are similar to mechanical vibration. during a line failure. This allows the circuit breaker
to trip in sequence.
Radio Suppression – Radio suppression reduces
the amplitude of radio frequency interference. Short – A short is an undesired electrical connection
that exists between two or more components.
Reciprocating – Reciprocating motion is motion that
first moves in a straight line in one direction. The Shutdown – A shutdown occurs when the engine is
direction of this motion then varies by 180 degrees. stopped. This shutdown can occur manually or this
shutdown can occur automatically.
Rectifier – A rectifier is a diode circuit that converts
alternating current (AC) to direct current (DC). Simultaneous – A simultaneous occurrence refers
to two actions that happen at the same time.
Rotating Rectifier – A rotating rectifier is mounted to
a plate on a generator shaft. This plate then rotates Solid-State – A solid-state component is an
with the generator shaft. electrical component that has no moving parts.
Regenerative Power – Regenerative power is power Stator – A stator is the windings of a generator that
that works against primary power. do not rotate.
Reset – A reset returns a switch to a ready Surge – A surge is a sudden increase in voltage
condition. In addition, a reset returns a circuit to or current.
a ready condition.
Tap – A tap is a connection at the midpoint of a
Residual Magnetism – Residual magnetism is a circuit. From this tap, power is taken from the circuit.
small amount of magnetism that is remaining in a
device after excitation is removed. Transfer – A transfer refers to moving something
from one point to another point. A transfer also
RFA – An RFA is a rotating field assembly. refers to converting something from one state to
another state.
Rotor – A rotor is the rotating windings of a
generator. Transient Peak Voltage – A transient peak voltage is
a high voltage condition of limited duration.
Saturable Reactor – A saturable reactor has
characteristics that are similar to a valve. As the Turn-on – When a device is turned on, the device is
load changes, a valve opens in order to give more activated or the device is started.
current to the output or a valve closes in order to
give less current to the output. Varistor – A varistor is a device that loses resistance
as voltage increases.
Saturated – A device has been saturated when
the device has been magnetized in excess. When Voltage Droop Resistor – A voltage droop resistor is
saturation occurs, a large increase in current results a variable resistor. This resistor is used to control the
in a small increase in magnetic force. change of voltage. This can occur when a generator
is paralleled with another generator. This can also
occur when the generator is paralleled with a utility.
27
Voltage Gain Resistor – A voltage gain resistor is a

variable resistor. This resistor is used to control the
change of voltage from no load to full load.
Voltage Level Rheostat – A voltage level rheostat

gives a range of control that is used when the
voltage output level is adjusted.
Voltage Spike – A voltage spike is a brief high

voltage.
Windings – Windings are layers of wire on a core.
Wiring – Wiring relates to the wires of a circuit.

28
Testing and Adjusting • The generator is a constant speed unit. An RPM

that varies can cause terminal voltages to vary.
Section When the rpm exceeds the rated rpm (5% to
10%), the terminal voltage could exceed the
rated output voltage (5% to 10%). When the rpm
is lower than the rated rpm (5% to 10%), the
Testing and Adjusting terminal voltage could be lower than the rated
output voltage (5% to 10%).
i01154940
• Generator heat is caused by line current. As the
line current increases, the generator temperature
General Information increases.
SMCS Code: 4450
• Instrumentation will not accurately show a
generator’s kVA load (including ammeters,
wattmeters, and voltmeters). This is because of
the power factor of the load.
Personal injury or death can result from high volt-
age.
i01157451
When power generation equipment must be in op-
eration to make tests and/or adjustments, high
Service Tools
voltage and current are present.
SMCS Code: 0785
Improper test equipment can fail and present a
high voltage shock hazard to its user.
Make sure the testing equipment is designed for Personal injury or death can result from high volt-
and correctly operated for high voltage and cur- age.
rent tests being made.
When power generation equipment must be in op-
When servicing or repairing electric power gener- eration to make tests and/or adjustments, high
ation equipment: voltage and current are present.
• Make sure the unit is off-line (disconnected Improper test equipment can fail and present a
from utility and/or other generators power high voltage shock hazard to its user.
service) , and either locked out or tagged DO
NOT OPERATE. Make sure the testing equipment is designed for
and correctly operated for high voltage and cur-
• Remove all fuses. rent tests being made.
• Make sure the generator engine is stopped.

• Make sure all batteries are disconnected.
• Make sure all capacitors are discharged.
Failure to do so could result in personal injury or
death. Make sure residual voltage in the rotor, sta-
tor and the generator is discharged.
When work is being done on a generator, the

following general rules should be used as a guide:
• Before you work on the generator, the operating

principles must be understood.
29
Table 9 i01155184
TOOLS NEEDED Troubleshooting

Part Tool Quantity
Number SMCS Code: 4450-035
6V-7070 Digital multimeter 1
Used to measure voltage,
resistance, or current up to 10
amperes. Rectifiers can be
checked by using the diode
function. Refer toSpecial
Instruction, SEHS7734.
9U-7330 Digital multimer (optional) 1
Used to measure voltage,
current, frequency, duty
cycle, and capacitance.
8T-0900 AC/DC clamp-on ammeter. 1
Used to measure current
up to 1200 amperes. When
measuring line current
on multiple lead units,
measure the current in each
conductor per phase and
add the currents together.
Refer to Special Instruction,
SEHS8420.
9U-6003 Insulation Tester 1
(megohmmeter)
Used to measure the
insulation resistance of
the main armature, main
field, exciter armature, and
exciter field.
g00555151
Illustration 45
A Milliohmmeter (Wheatstone 1
Bridge) PMPE Generator Wiring Diagram
Used to measure the winding (CR1 through CR6) Rectifiers
resistance of the main (CR7) Varistor
armature and the exciter field. (L1) Exciter field (stator)
(L5) Pilot exciter armature
(PM) Permanent magnet
(CST) Customer supplied transformer
(T1, T2, T3) Generator terminals and/or generator leads
This section provides probable causes to a known

problem. There may be several probable causes
to each problem. Specific inspections or tests are
recommended in order to help isolate the damaged
component.
The generator is a component of the generator

set. The generator should be tested with the entire
system. The voltage regulator’s service manual
provides tests in order to determine if the generator
is the cause of a generator set malfunction.
A problem must be identified and defined before

the problem can be corrected. After you identify the
problem, refer to Table 10.
The following procedure should be used to identify

the problem:
30
1. Perform Visual Checks in order to help identify Problem List

the problem.
Table 10
2. If previous tests were performed from the voltage PROBLEM PROBABLE REFERENCE
regulator service manual, use the test results to CAUSE
help identify the problem.
All Phase Damaged diodes “Rotating
Voltages Are (CR1 through Rectifier - Test”
3. Perform the Generator Functional Test. The
Too Low. CR6)
Generator Functional Test will help identify the
problem. Damaged exciter “Winding - Test”
armature (Rotor
- L2)
Visual Checks
Damaged exciter “Winding - Test”
A visual inspection of the generator set can detect field (Stator - L1)
possible causes of a malfunction. Inspect all wiring Damaged PM “Winding - Test”
for worn insulation or missing insulation. Ensure that armature (L5)
all wire terminal connections are tight. Also ensure
that all wire terminal connections are not corroded. Damaged “Varister - Test”
Discolored electrical components indicate that the varistor (CR7)
item has been greatly stressed. The Phase Damaged main “Winding - Test”
Voltages Are armature (Stator
A large percentage of electrical problems are Not Equally - L4)
caused by mechanical defects. Carefully inspect Balanced.
the total installation. Keep the mechanical defects The Phase Damaged diodes “Rotating
separate from the electrical defects. Voltages Do Not (CR1 through Rectifier - Test”
Change With CR6)
Engine Speed.
Damaged Exciter “Winding - Test”
armature (Rotor
- L2)
Damaged exciter “Winding - Test”
field (Stator - L1)
Damaged PM “Winding - Test”
armature (L5)
i01699662
Generator Set - Test

SMCS Code: 4450-081
Table 11
TOOLS NEEDED
Part Number Tool Quantity
6V-7070 Digital 1
Multimeter
12 VDC Battery 1
31
NOTICE
Do not operate the generator set at a speed that is
higher than one-half of the rated speed.
Higher speeds under these test conditions can cause

damage to the system.
Note: Do not allow the generator output voltage to

exceed the nameplate rating.
3. Operate the generator set at half the rated

speed.
4. Measure the AC voltage across the following

terminals. Record the results.
Table 12
AC VOLTAGE ACROSS TERMINALS
g00613756
Generator Set Terminals AC Voltage
Illustration 46 Speed
Voltage Regulator
Half of the Rated “T1” and “T2”
Speed
“T1” and “T3”
“T2” and “T3”
Decrease “T1” and “T2”
Generator Set
Speed by 10%. “T1” and “T3”
“T2” and “T3”
Increase “T1” and “T2”
Generator Set
Speed by 10%. “T1” and “T3”
Do Not Exceed “T2” and “T3”
Half of the
Rated Speed.
g00613767
Illustration 47
Terminals
5. Monitor the same voltages as Step 4, while
decreasing and then increasing the generator
The generator set functional test is a simplified test set speed 10%. Do not exceed half of the rated
that can be performed in order to determine if the speed.
generator is functional. The final test should be on
the complete generator set while the generator is 6. The measured voltages of Step 4 should be at
under load. The generator set functional test will least 85 VAC. With a 10% increase in generator
determine if a phase voltage is being generated. set speed, the voltages of Step 5 should show
The generator set functional test will also determine an increase of 10%. With a 10% decrease in
if the phase voltages are balanced. In addition, this generator set speed, the voltages of Step 5
test will determine if the phase voltages change should show a decrease of 10%.
with engine speed.
Note: If the engine speed cannot be adjusted to
The generator set functional test consists of the half of the rated speed, a 6 VDC battery can be
following steps: used. The 6 VDC battery would be connected to
wires F1+ and F2- in Step 2.
1. Disconnect wires F1 and F2 from the voltage
regulator. Disconnect the generator load.
2. Connect a 12 VDC automotive type battery to

wires F1+ and F2-.
32
i01699677 Six-Diode Rectifier Block

Varistor - Test
SMCS Code: 4466-081
Table 13
TOOLS NEEDED
6V-7070 Digital 1
Multimeter
g00613957
Illustration 49
Six-Diode Rectifier Block (one piece)
(1) Positive Rectifier Block
(2) Negative Rectifier Block
(3) Rectifier Terminal “AC1”
The following procedure tests all six diodes within

the block. If any meter reading does not fall within
the given ranges, replace the rectifier block .
1. Set the digital multimeter on the diode range.

Remove all leads from the rectifier block.
2. Place the black test lead on the positive “+”

rectifier terminal. Place the red test lead on the
following rectifier terminals: “AC1”(3), “AC2”(4),
Illustration 48 g00610379 and “AC3”(5). All readings on the meter should
Varistor (CR7)
be between 0.4 and 1.0.
Varistor (CR7) can be checked by measuring the 3. Place the red test lead on the negative “-”
resistance between the positive “+” terminal and rectifier terminal. Place the black test lead on the
the negative “-” terminal. The resistance should following rectifier terminals: “AC1”(3), “AC2”(4),
equal 15000 ohms or the resistance should exceed and “AC3”(5). All readings on the meter should
15000 ohms. be between 0.4 and 1.0.
Note: For testing rectifier blocks with integral varistor 4. Place the red test lead on the positive “+”
(CR7), refer to Testing And Adjusting, “Rotating rectifier terminal. Place the black test lead on the
Rectifier - Test”. following rectifier terminals: “AC1”(3), “AC2”(4),
and “AC3”(5). In all cases, the meter should read
“OL” (overload).
i01155464
5. Place the black test lead on the negative “-”
Rotating Rectifier - Test rectifier terminal. Place the red test lead on the
following rectifier terminals: “AC1”(3), “AC2”(4),
SMCS Code: 4465-081 and “AC3”(5). In all cases, the meter should read
“OL” (overload).
Table 14
TOOLS NEEDED Note: A shorted diode can cause damage to the
exciter rotor. If a diode is shorted, check the exciter
rotor. Refer to the Testing and Adjusting, “Winding -
6V-7070 Multimeter 1 Test” and Testing and Adjusting, “Insulation - Test”.
Perform these tests.
33
Note: This rectifier block also contains varistor 1. Set the digital multimeter on the diode range.
“CR7”. “CR7” can be checked by measuring the Remove all leads from the rectifier block.
resistance between the positive “+” rectifier terminal
and the negative “-” rectifier terminal. The resistance 2. To test the negative rectifier block, follow these
should be a minimum of 15000. steps:
a. Place the red test lead on the negative

Three-Diode Rectifier Block “-” terminal. Place the black test lead on
the following rectifier terminals: “AC1”(3),
“AC2”(4), and “AC3”(5). All readings on the
meter should be between 0.4 and 1.0.
b. Place the black test lead on the negative

“-” terminal. Place the red test lead on
the following rectifier terminals: “AC1”(3),
“AC2”(4), and “AC3”(5). In all cases, the
meter should read “OL” (overload).
3. To test the positive rectifier block, follow these

steps:
a. Place the red test lead on the positive “+”

rectifier terminal. Place the black test lead
on the following rectifier terminals: “AC1”(3),
“AC2”(4), and “AC3”(5). In all cases, the
meter should read “OL” (overload).
b. Place the black test lead on the positive “+”

g00610240
rectifier terminal. Place the red test lead on
Illustration 50 the following rectifier terminals: “AC1”(3),
Three-Diode Rectifier Block (two pieces) “AC2”(4), and “AC3”(5). All readings on the
meter should be between 0.4 and 1.0.
Note: A shorted diode can cause damage to the

Test” and Testing and Adjusting, “Insulation - Test”.
Note: This rectifier block also contains varistor

“CR7”. “CR7” can be checked by measuring the
resistance between the positive “+” rectifier terminal
and the negative “-” rectifier terminal. The resistance
should be a minimum of 15000.
g00613971
Illustration 51
Three-Diode Rectifier Block (two pieces)
The following procedure tests all three diodes within

a block. Check the positive rectifier block and the
negative rectifier block. If any meter reading does
not fall within the given ranges, replace the rectifier
block.
34
Two-Diode Rectifier Block Note: A shorted diode can cause damage to the
Test” and Testing and Adjusting, “Insulation - Test”.
g00610186
Illustration 52
Two-Diode Rectifier Block (three pieces)
The following procedure tests both diodes within

the block. Perform this procedure on all three of
the two diode rectifier blocks. If any meter reading
does not fall within the given ranges, replace the
rectifier block.
1. Set the digital multimeter on the diode range.

Remove all leads from the rectifier block.
2. Place the black test lead on the AC rectifier

terminal.
a. Place the red test lead on the negative “-”

rectifier terminal. The reading on the meter
should be between 0.4 and 1.0.
b. Place the red test lead on the positive “+”

should be “OL” (overload).
3. Place the red test lead on the AC rectifier

terminal.
a. Place the black test lead on the negative “-”

should be “OL” (overload).
b. Place the black test lead on the positive “+”

should be between 0.4 and 1.0.
35
i01699685 Measure the resistance of the following windings:

(L1), (L2), (L3), (L4), and (L5). The winding that
Winding - Test is being tested must be disconnected from the
other components before the resistance can be
SMCS Code: 4453-081; 4454-081; 4457-081; measured.
4470-081
Note: The winding temperature affects the
resistance. When the winding temperature
increases, the winding resistance increases.
When the winding temperature decreases, the
winding resistance decreases. Therefore, a correct
measurement can be performed only when the
winding is at room temperature.
The following resistance measurements are

approximations. If the measured value is not near
the listed approximation, the winding is probably
damaged. For a more precise resistance value,
consult the Technical Marketing Information (TMI).
Refer to the generator arrangement that is in
question.
The following armature windings have very little

resistance: (L2), (L4), and (L5). The resistance of
these windings will measure near 0 ohms. Use a
milliohmmeter to measure the resistance of the
armature windings.
Exciter Armature (Rotor) (L2) – less than 0.1 ohm
Main armature (Stator) (L4) – less than 0.1 ohm
Pilot Exciter Armature (L5) – less than 0.1 ohm
Use a multimeter in order to measure the resistance

of field windings (L1) and (L3).
Exciter Field (Stator) (L1) – approximately 3.0 ohms

to 6.0 ohms
Illustration 53 g00874841 Main Field (Rotor) (L3) – approximately 0.75 ohms

PMPE Generator Wiring Diagram to 2.0 ohms
(CR1-C6) Diodes
Note: There should be no continuity between any
(CR7) Varistor winding and ground. There should be no continuity
(L1) Exciter Field (Stator) between any winding and another winding.
(L2) Exciter Armature (Rotor)
(L3) Main Field (Rotor)
(L4) Main Armature (Stator)
(L5) Pilot Exciter Armature
(PM) Permanent Magnet
(RFA) Rotating Field Assembly
(CT1)Optional Voltage Droop Transformer
(T0, T1, T2, T3, T7, T8, T9) Generator Terminals
Table 15
TOOLS NEEDED
Digital
6V-7070 1
Multimeter
36
i01699697 Table 16
Insulation - Test TOOLS NEEDED

SMCS Code: 4453-081; 4454-081; 4457-081;
4470-081 142-5055 Insulation Tester 1
Megohmmeter
Personal injury or death can result from electrocu-

tion.
The megohmmeter is applying a high voltage to

the circuit.
To avoid electrocution, do not touch the instru-

ment leads without first discharging them. When
finished testing also discharge the generator
windings.
The following materials will cause the winding

insulation to deteriorate:
• moisture (water)
• dust
• grease
• other foreign matter within the generator
This deterioration reduces the resistance of the
insulation. This test will measure the resistance of
the winding insulation.
The insulation tester (megohmmeter) produces

a high potential voltage between the test leads.
During the test, a small current flows. The tester
Illustration 54 g00874841 converts this current to a resistance reading.
The insulation test is performed as part of periodic
(CR1-C6)Diodes maintenance in order to detect the deterioration
(CR7) Varistor of the winding insulation. When there is a rapid
(L1) Exciter Field (Stator) decrease in the insulation resistance in a short
(L2) Exciter Armature (Rotor) amount of time, the generator needs to be cleaned.
Note: For information on generator cleaning, refer
(L4) Main Armature (Stator) to Special Instruction, SEHS9124.
(PM) Permanent Magnet When generators have not been used for a period
(RFA) Rotating Field Assembly of time, moisture can accumulate. Therefore, the
(CT1) Optional Voltage Droop Transformer
insulation test should be performed on generators
that have been idle. If moisture is known to exist,
(T0, T1, T2, T3, T7, T8, T9) Generator terminals
the windings must be dried prior to testing. Refer to
Testing And Adjusting, “Generator - Dry”.
The winding needs to be reconditioned or the

winding needs to be replaced in the following
cases:
37
• The measured insulation resistance falls below 2. Connect one test lead of the insulation tester
the specified amount. The cleanup procedure (megohmmeter) to the generator enclosure
does not correct the discrepancy. (ground).
• The measured insulation resistance falls below 3. Connect one test lead of the insulation tester
the specified amount. The drying procedure does (megohmmeter) to exciter field lead (F1 or F2).
not correct the discrepancy.
4. Measure the resistance of the exciter field
The specified insulation resistance is an winding insulation to ground. The insulation
approximate value. It can be possible to operate resistance must be a minimum of 0.25 megohm
the generator with less than the specified value. (250000 ohms).
However, a generator that has a low winding
insulation resistance will be more likely to have a Exciter Armature (Rotor L2)
failure.
1. Isolate exciter armature (L2) from the rectifier
circuit. Disconnect the three wires of the exciter
armature from the rectifier blocks.
Personal injury or death can result from improper
troubleshooting and repair procedures. 2. Connect one test lead of the insulation tester
(megohmmeter) to the rotor shaft.
The following troubleshooting and repair proce-
dures should only be performed by qualified per- 3. Connect one test lead of the insulation tester
sonnel familiar with this equipment. (megohmmeter) to any one exciter field lead.
4. The insulation resistance must be a minimum of

The insulation test gives accurate results only when
0.25 megohm (250000 ohms).
the generator windings are free of moisture and the
generator windings are at room temperature.
Pilot Exciter Armature L5
Each winding must have a minimum insulation
resistance of one megohm. 1. Isolate pilot exciter armature (L5) from the
voltage regulator. Disconnect wires 26, 28, and
30 of the pilot exciter from the termination points.
Main Armature (Stator L4) These wires are usually fused. These wires
connect to a terminal strip or these wires connect
1. Remove the load from the generator by either
to the voltage regulator.
opening the line circuit breaker or the load
connections to (T1), (T2), (T3), and (T0). Prevent
2. Connect one test lead of the insulation tester
these wires from coming into contact with each
(megohmmeter) to the generator enclosure
other and prevent these wires from contacting
(ground).
ground.
3. Connect the other test lead of the insulation
2. Isolate main armature (L4) from the voltage
tester (megohmmeter) to any one lead of the
regulator by disconnecting wires 20, 22, and
pilot exciter armature.
24. If generator lead (T0) is connected to the
generator frame or ground, open the connection.
4. The insulation resistance must be a minimum of
0.25 megohm (250000 ohms).
3. Connect one test lead of the insulation tester
(megohmmeter) to the generator enclosure
(ground).
4. Connect the other test lead of the insulation

tester (megohmmeter) to generator lead (T0).
5. The insulation resistance must be one megohm

or more.
Exciter Field (Stator L1)

1. Isolate exciter field (L1) from the voltage regulator
by disconnecting wires F1 and F2. Prevent these
wires from coming into contact with each other
and prevent these wires from contacting ground.
38
i01699707 Table 17
Resistor - Test TOOLS NEEDED

SMCS Code: 1437-081
6V-7070 Digital 1
Multimeter
Resistor (R5) is used on generators that have three

diode rectifier blocks.
The Resistor Test consists of the following steps:
1. Disconnect one lead of resistor (R5) from the

positive terminal of varistor (CR7).
2. Connect one test lead of the multimeter to each

lead of the resistor.
3. Resistor (R5) should measure 27000 ohms (±

2700 ohms).
i01699710
Generator - Dry
SMCS Code: 4450-569
NOTICE
Do not operate the generator if the windings are wet. If
the generator is operated when the windings are wet,
damage can occur due to insulation breakdown.
When moisture is present or when moisture is

suspected in a generator, the generator must be
dried before being energized. For information on
drying the generator, refer to Testing And Adjusting,
“Insulation - Dry”.
g00874841
Illustration 55
PMPE Generator Wiring Diagram If the drying procedure does not restore the
insulation resistance to an acceptable value, the
(CR1-C6)Diodes
winding should be reconditioned.
(CR7) Varistor
(L1) Exciter Field (Stator) Note: For additional information, refer to Special
(L2) Exciter Armature (Rotor) Instruction, SEHS9124 .
(L4) Main Armature (Stator) Drying Methods
(PM) Permanent Magnet The following methods can be used for drying a
generator:
(R5)Resistor
(RFA) Rotating Field Assembly
• Self-circulating air method
(T0, T1, T2, T3, T7, T8, T9) Generator terminals • Oven method
• Controlled current method
39
Heat can be used in order to dry the generator

NOTICE windings. This heat can be created by allowing a
Do not allow the winding temperature to exceed 85 C controlled current to flow through the generator. No
(185.0 F). Temperatures that are greater than 85 C high voltages are generated during the following
(185.0 F) will damage the winding insulation. procedure. Therefore, insulation breakdown will not
occur.
Self-Circulating Air Method 1. Make an external power source. Refer to

Illustration 56.
Run the engine and disconnect the generator load.
This will help circulate air. Operate the generator 2. Disconnect F1+ from the voltage regulator.
space heaters. Disconnect F2- from the voltage regulator.
Disconnect the generator load. Connect the
Oven Method generator output leads T0, T1, T2, and T3
together. Install the clamp-on ammeter to
Place the entire generator inside a forced air drying generator output lead T1.
oven for four hours at 65 C (149 F).
Note: When the line current is measured on multiple
lead units, measure the current in each conductor
NOTICE per phase. The currents can then be added.
Use a forced air type oven rather than a radiant type
oven. 3. Refer to Illustration 56. Adjust the rheostat to the
maximum resistance value. Connect the external
Radiant type ovens can cause localized overheating. power source to wires F1+ and F2-.
4. Start the generator set. Run the generator set

Controlled Current Method at idle speed.
NOTICE
Do not exceed the rated phase current that is listed on
the generator nameplate. Exceeding the rated phase
current will easily damage the generator windings.
5. Monitor the phase current. Gradually increase

the engine RPM. Increase the engine RPM until
one of the following conditions are met:
• The rated phase current is obtained.

• The full generator set speed is obtained.
g00614674
Illustration 56
6. If more phase current is necessary, slowly turn
External Power Source Circuit
the rheostat. Turn the rheostat until the rated
(1) Battery (12 VDC) phase current is reached.
(2) Rheostat (15 Ohm 25 watt)
(3) Exciter field (stator “L1”)
7. On an hourly basis, stop the drying procedure.
Table 18 Check the insulation resistance. Repeat the
above steps until the insulation resistance is
TOOLS NEEDED acceptable.
8T-0900 Clamp-on 1
Ammeter (1200
amperes)
External Power 1
Source Circuit
40
i01699714 2. After connecting the leads to the bus bar, group

all generator phase leads together. Tie these
Leads - Connect leads together.
SMCS Code: 4459-077 Ensure that there is a minimum clearance of 25 mm
(1.0 inch) between uninsulated connections (phase
Generator Leads To Terminal Strips to phase and phase to ground).
Generator Lead To Other Lead
g00613767
Illustration 57
Terminal Strips
g00614361
Illustration 59
Lead To Lead Connection (Generators with medium voltage or
less)
(1) Plated washer
Table 19
TOOLS NEEDED
5N-4685 Varnished cambric 1
electric tape
15000 volt rating
105 C (221.0 F) rating
5N-4686 Black vinyl plastic 1
electrical tape
−40 C (−40.0 F) to
80 C (176.0 F) rating
When connecting the generator leads together or

when connecting generator leads to a load lead,
g00614345
use the following procedure:
Illustration 58
Terminal Strip Lead Connections 1. Fasten the generator leads together by using
(1) Generator leads flat plated washer (1) under the bolt head and
(2) Terminal strip (Bus Bar) under the nut.
(3) Plated washer
2. Apply two layers of varnished cambric high
Attach the generator leads (1) to terminal strip (2) voltage tape. When the tape is being wrapped,
in the following manner: the tape must be overlapped. The tape must
be overlapped 50% of the width of the tape.
1. When more than one lead attaches to the bus Taping must extend length “B” onto the lead
bar, place the leads on each side of the bus bar. wire insulation. Length “B” is equal to 25 mm
Use flat plated washer (3) under the bolt head (1.0 inch).
and under the nut.
41
3. Apply two layers of vinyl plastic electrical tape i01699728

over the varnished cambric high voltage tape.
Taping must extend length “A” onto the lead Exciter Field - Flash
wire insulation. Length “A” is equal to 51 mm
(2.0 inches). SMCS Code: 4470
4. The generator leads must not contact the sheet

metal of the terminal box or any rotating parts.
For each generator phase, group the leads
together. Secure the leads together with cable
straps.
g00874825
Illustration 60
Wiring Diagram of the Self-Excited Generator
(CR1-C6) Diodes
(CR7) Varistor
(T0, T1, T2, T3, T7, T8, T9) Generator terminals
Self-excited generators may lose the residual

magnetism that normally exists in the exciter field
(L1) and the main field (L3). Residual magnetism
is necessary to start the generation process. The
magnetism can be restored by flashing exciter field
(L1) with direct current. A 6 VDC battery can be
used to supply the direct current.
42
Dynamic Flashing (Running

NOTICE Engine)
Do not flash permanent magnet pilot excited (PMPE)
generators. Damage to the generator set can occur.
There are two methods of flashing the field:
• Static Flashing (stopped engine)

• Dynamic Flashing (running engine)
Static Flashing (Stopped Engine)

Table 20
TOOLS NEEDED
Tool Quantity g00614470
Illustration 61
6 VDC Battery 1 Dynamic Flashing Circuit
(1) Battery (≤ 6 VDC)
1. Stop the engine. (2) Diode
(3) Red test lead “+”
(4) Black test lead “-”
2. At the voltage regulator, disconnect wire F1 GEN
from terminal F1 and disconnect wire F2 GEN Table 21
from terminal F2.
TOOLS NEEDED
3. Connect the positive cable of the 6 volt source to Part Number Tool Quantity
wire F1 GEN.
6V-7070 Digital 1
Multimeter
4. Momentarily put the negative cable of the 6 volt
source on wire F2 GEN (two or three times). 9P-5153 Diode 1
(MR-504)
Note: Do not hold the negative cable to wire F2 Dynamic 1
GEN for more than one or two seconds. Flashing Circuit
5. Connect all wires that were previously

disconnected. 1. Construct the dynamic flashing circuit that is
shown in Illustration 61.
2. Stop the engine.
3. Connect a multimeter (set on ACV) to terminals

20 and 22 at the voltage regulator.
4. Start the engine and run the engine at low idle.
NOTICE
Do not hold the flashing circuit’s test leads on the ter-
minals longer than necessary. This can cause the volt-
age to become too high. Excessive voltage can cause
damage to the generator and can cause damage to
the flashing circuit.
5. Hold the red lead of the dynamic flashing circuit

to terminal F1.
6. Monitor the voltmeter. Touch the black lead to

terminal F2 of the dynamic flashing circuit.
43
7. When the voltmeter shows an increase in voltage,

remove the test leads from terminal F1 and
terminal F2. If the generator voltage does not
increase within 5 to 10 seconds, remove the test
leads from terminals F1 and F2.
44
Disassembly and Assembly

Section
i01162628
Exciter - Remove and Install

SMCS Code: 4454-010
Removal Procedure
Remove The Exciter Field and Remove
The Exciter Armature Illustration 64 g00619563
Terminal Strip
“F1” and “F2” first terminate at a terminal strip.
(1) Wires “F1” and “F2”
2. Disconnect exciter wires (“F1” and “F2”) from the

first termination point. These wires terminate at
the voltage regulator or at a terminal strip.
For permanent magnet pilot excited generators,

disconnect wires “26”, “28”, and “30” from the
first termination point. These wires first terminate
at fuses. These fuses are located on a terminal
strip or these fuses are located in the harness.
g00619102
Illustration 62 Pull the disconnected wires from the harness
400 Frame bundles and place the disconnected wires near
the exciter field.
1. Remove the side and rear access panels from
the generator.
g00619571
Illustration 65
Two-Diode Rectifier Blocks (Three Pieces)
g00619559
Illustration 63
Voltage Regulator
“F1” and “F2” first terminate at a voltage regulator.
45
g00619585 g00619592
Three-Diode Rectifier Block (One Piece) Generator with Outboard PM Pilot Exciter
(4) Bolts
(5) Mounting Assembly
(6) Retainer
4. On generators with an outboard PM pilot exciter,

perform the following procedure:
a. Remove four bolts (4) which fasten retainer (6)

and mounting assembly (5) to the rotor shaft.
b. Remove retainer (6) and mounting assembly

(5). Ensure that the diode rectifier blocks
remain attached.
g00619588
Illustration 67
Six-Diode Rectifier Block (One Piece)
(2) Screws
3. Various rectifier blocks and mounting hardware

are used. The rectifier blocks and the mounting
plate must be removed in order to remove the
exciter. Disconnect the two generator leads from
the rectifier blocks. Also, disconnect the three
exciter leads from the rectifier blocks.
For generators with the six-diode rectifier block, g00619603

Illustration 69
remove two allen head screws (2) which fasten
the six-diode rectifier block and mounting Generator with Outboard PM Pilot Exciter
assembly (3) to the rotor shaft. Remove the (7) Bolts
six-diode rectifier block and mounting assembly (8) Rotating Pilot Exciter Field
(9) Stationary Pilot Exciter Armature
(3).
Note: The magnetism between pilot exciter armature

(9) and pilot exciter field (8) is very strong. The
components may come off at the same time.
a. Remove four bolts (7) which fasten stationary

pilot exciter armature (9) to the generator.
b. Remove stationary pilot exciter armature (9)

and rotating pilot exciter field (8).
46
g00619613 g00619644
Shroud and Exciter Field Generator with Outboard PM Pilot Exciter
(10) Shroud (16) Bolt
(11) Exciter Field (17) Exciter Field
(12) Bolts
6. If equipped, remove four bolts (12) which perform the following procedure:
fasten shroud (10) and exciter field (11) to the
generator. Remove shroud (10) (if equipped) and a. Remove four bolts (16) which fasten exciter
exciter field (11) from the generator. field (17) to the generator.
b. Remove exciter field (17).
g00620388
Illustration 71
Retainer and Exciter Armature
g00619666
(13) Exciter Armature Illustration 73
(14) Retainer Generator with Outboard PM Pilot Exciter
(15) Bolts
(18) Exciter Armature
(19) Spacer
7. Four bolts (15) and a retainer (14) are used to
fasten the exciter armature (13) to the rotor shaft. 9. On generators with an outboard PM pilot exciter,
Remove the four bolts and remove the retainer. perform the following procedure:
While the retainer is being removed, carefully
pass the generator leads through the retainer’s a. Carefully slide spacer (19) off the rotor shaft.
opening. Remove exciter armature (13) from the
rotor shaft. b. As the spacer is slid off the rotor shaft, ensure
that the spacer clears the exciter leads.
c. Remove exciter armature (18) from the rotor

shaft.
47
a. Slide stationary pilot exciter armature (20)

and rotating pilot exciter field (21) over the
rotor shaft.
b. Use four bolts (23) in order to fasten the

stationary pilot exciter armature (20) to the
generator.
c. Slide spacer (22) on the rotor shaft.

g00619669
Illustration 74
Generator with Inboard PM Pilot Exciter
(20) Pilot Exciter Armature
(21) Pilot Exciter Field
(22) Spacer
(23) Bolts
Note: The magnetism between pilot exciter armature

(20) and pilot exciter field (21) is very strong. The
components may come off at the same time.
10. Slide spacer (22) off the rotor shaft.

g00619666
Illustration 76
11. Remove four bolts (23) which fasten stationary
Generator with Outboard PM Pilot Exciter
pilot exciter armature (20) to the generator.
(19) Spacer
12. Remove stationary pilot exciter armature (20)
and rotating pilot exciter field (21).
a. Slide exciter armature (18) on the rotor shaft.
Installation Procedure b. As the spacer is slid on the rotor shaft, ensure

that the spacer clears the exciter leads.
Install The Exciter Field and Install The
Exciter Armature c. Carefully slide spacer (19) on the rotor shaft.
1. On generators with an inboard PM pilot exciter, 3. On generators with an outboard PM pilot exciter,
perform the following procedure: perform the following procedure:
g00619644
g00619669 Illustration 77
Illustration 75
Generator with Inboard PM Pilot Exciter
a. Place exciter field (17) on the generator.
(20) Pilot Exciter Armature
(21) Pilot Exciter Field
(22) Spacer
b. Use four bolts (16) to fasten the exciter field
(23) Bolts to the generator.
48
4. Slide exciter armature (13) on the rotor shaft.
g00619613
Illustration 79
g00620388
Illustration 78 Shroud and Exciter Field
Retainer and Exciter Armature (10) Shroud
(11) Exciter Field
(12) Bolts
(14) Retainer
(15) Bolts
7. Use four bolts (12) to attach shroud (10) (if
5. A retainer (14) is used to fasten the exciter equipped) and exciter field (11) to the generator.
armature (13 ) to the generator. Carefully pass the
generator leads through the retainer’s opening.
6. Use four bolts (15) to fasten the retainer to the

generator.
Note: When the exciter armature (13) is installed,

the bolts (15) must be properly tightened.
Apply 9S-3263 Thread Lock to the bolts (15)

before the bolts are installed. Refer to Table 22
for information regarding bolt torque.
Table 22
BOLT TORQUE g00619603
Illustration 80
Bolt Size Torque Generator with Outboard PM Pilot Exciter
5/16 inch 35.4 N·m (26.11 lb ft) (7) Bolts
(8) Rotating Pilot Exciter Field
3/8 inch 55.8 N·m (41.16 lb ft) (9) Stationary Pilot Exciter Armature

a. Place stationary pilot exciter armature (9) and

rotating pilot exciter field (8) on the generator.
b. Use four bolts to attach the stationary pilot

exciter armature (9) and rotating pilot exciter
field (8) to the generator.

49
i01161961
Generator - Remove
SMCS Code: 4450-011
Removal Procedure
g00619592
Illustration 81
Generator with Outboard PM Pilot Exciter
(4) Bolts
(6) Retainer
a. Slide mounting assembly (5) and retainer (6)

over the rotor shaft. Illustration 82
g00619076
(1) Stationary pilot exciter armature

b. Use four bolts to attach the mounting (2) Rotating pilot exciter field
assembly (5) and retainer (6) to the rotor shaft.
Note: This procedure describes removing the
10. Various rectifier blocks and mounting hardware generator terminal box from the generator. Some
are used. The rectifier blocks and mounting service operations do not require the removal of
plates must be installed after the exciter is the generator terminal box. The removal of the
attached. generator terminal box may not be necessary.
End By:
a. Connect the two generator leads to the rectifier

blocks.
b. Connect the three exciter leads to the rectifier

blocks.
c. For permanent magnet pilot excited generators,

connect wires “26”, “28”, and “30” to the first
termination point.
d. Connect exciter wires (“F1” and “F2”) to the first

termination point.
g00619082
Illustration 83
e. Install the side and rear access panels to the Generator Terminal Box with a Typical 600 Frame
generator.
50
g00619102 g00619154
Generator Terminal Box with a Typical 400 Frame Terminal Strips (Control Panel interior)
1. Remove the side and rear panels of the generator 2. To remove the generator terminal box, disconnect
terminal box in order to access the wiring. all the wiring that extends from the generator
terminal box to the generator or to the engine.
Disconnect the following wires:
• engine harness wires

• generator leads
• current transformer wires
• temperature sensing wires
• space heater wires
• ground wires
g00619117
Illustration 85 Remove the engine harness from the generator
Terminal Strips (DIN) terminal box.
Most of the wiring can be disconnected at the

terminal strips. The exact location of the terminal
strips and the type of terminal strips varies
with the different generator set packages. The
preceding illustrations show some of the various
terminal strips.
3. To remove the generator terminal box, remove

the lower rear panel and the screen beneath the
rear of the generator.
g00619124
Illustration 86
Terminal Strips
51
g00619180 g00619203
Generator Terminal Box (Typical 600 Frame) Generator support
(4) Support Beam
6. If there are no supports between the base of

the generator set and the flywheel end of the
engine, perform this Step. For supporting the
engine during removal of the generator, use one
of the following devices:
• hoist
• jack
• support beam (4)
g00619185
Illustration 89
Generator Terminal Box (Typical 400 Frame)
4. Attach a hoist to the four corners of the generator

terminal box.
g00621148
Illustration 92
Generator ground strap
(5) Ground strap
(6) Bolt
7. Remove bolt (6) that attaches ground strap (5)

g00619192 to the generator.
Illustration 90
Top View
(3) Bolt
5. Remove bolts (3) which fasten the generator

terminal box to the mounting brackets. Use
the hoist to lift the generator terminal box and
remove the generator terminal box.
52
g00619206 g00619267
(7) Screen (12) Bolts
(8) Shield (13) Coupling Plate
(9) Bolts
13. Separate the generator from the engine.
8. Attach a hoist to the generator. The point of Remove the generator. Place the generator on
attachment varies with the size of the generator. solid blocking material which will not allow the
A strap must be used on smaller generators generator to roll.
when no shackle is provided.
14. Remove bolts (12) which fasten coupling plate
9. Remove bolts (9) which fasten the generator to (13) to the rotor. Remove coupling plate (13).
the base.
10. Remove shield (8) and screen (7).
g00619275
Illustration 96
(14) Shims
(15) Fan
g00619261
Illustration 94
(10) Bolts 15. Remove shims (14) from the rotor shaft. If the
(11) Bolts fan (15) is not attached to the rotor, remove the
fan from the generator housing.
11. Remove bolts (11) which fasten the fan and the
coupling plate to the engine flywheel.
12. Remove bolts (10) which fasten the generator

housing to the flywheel housing.
53
i01159488 2. In order to manually rotate the engine, remove

the timing pointer’s cover from the engine’s
Generator - Install flywheel housing. Install dial indicator group (3).
Refer to Illustration 98. The tip of the indicator
SMCS Code: 4450-012 must touch the face of crankshaft pulley (4). Use
a bar between the flywheel and the flywheel
Installation Procedure housing in order to push the crankshaft toward
the flywheel. This will remove all the end play.
Put the dial indicator in the ZERO position. Move
All Generator Sets Except 3500 Engine
the crankshaft to the most forward position. Make
Family a record of the total indicator reading (TIR). The
TIR is the end play of the crankshaft.
Table 23
TOOLS NEEDED
8S-2328 Dial Indicator 1
Group
g00616727
Illustration 99
(5) Shim Pack
g00616707
Illustration 97
(1) Flywheel Pilot Bore
(2) Surface
1. Remove all dirt, burrs, and paint from the contact

surfaces of the generator supports and the base.
Remove the protection material (compound)
from flywheel pilot bore (1) and from surface
(2). There should be no protection material that
makes contact with the coupling. All contact
surfaces of the engine, the coupling, and the
g00616734
generator must be completely clean. Illustration 100
(6) Plate Assembly
(7) Bolts
NOTICE
Do not run the generator set unless the plate assembly
has the correct clearance. If the plate assembly does
not have the correct clearance, damage can occur to
the engine and/or generator.
3. Before installation, temporarily position plate

assembly (6) in the bore of the flywheel to check
for clearance. There must be clearance between
the plate assembly’s outside diameter and
the flywheel bore’s inside diameter. The plate
g00295967 assembly (6) can be a single solid plate or the
Illustration 98
(3) Dial Indicator Group plate assembly can be numerous flexible plates.
(4) Crankshaft Pulley
54
4. Install a full shim pack (5) and plate assembly

(6) on the generator with bolts (7). Tighten the
bolts to the torques that are shown in Table 24.
Table 24
REQUIRED TORQUE
Engine Torque
D379, G379, D398, G398, 505 ± 45 N·m
D399, G399 (372.0 ± 33.0 lb ft)
All other engines Standard torque
Note: Incorrect torque of bolts (7) can distort

the shims which may reduce rotor bearing end g00295971
Illustration 102
play. When the shims are assembled to the drive
coupling, the bolts (7) must be tightened to the (9) Bolts
(10) Bolts
correct torque.
7. Install bolts (9) and (10). Tighten bolts (9) and
Note: The total thickness of shims (5) must not
(10).
cause a reduction of crankshaft end play. When the
generator is installed, the total thickness of shims
(5) must not cause bending of plate assembly (6).
g00295967
Illustration 103
g00295970 8. Install dial indicator group (3) in order to measure

Illustration 101
crankshaft end play at crankshaft pulley (4).
(8) Guide Bolt In order to remove all end play, place a bar
between the flywheel and the flywheel housing.
5. Install guide bolt (8) in the flywheel. Push the crankshaft toward the flywheel. Put the
dial indicator in the ZERO position. Move the
6. Put the generator in position on the engine. crankshaft to the most forward position and make
a record of the total indicator reading (TIR). Do
not use force to hold the crankshaft in position.
The TIR is the end play of the crankshaft.
If the amount of end play is equal to the end play

that was measured in Step 2, proceed to Step 11.
If the crankshaft end play is NOT equal to the

original amount that was measured in Step 2,
go to Step 9.
55
g00616727
Illustration 104
9. Remove the generator. Remove shims (5) until

the original amount of end play is reached. Refer
to Step 2.
10. Install the generator and again check the

crankshaft end play. Repeat Step 8.
g00616719
Illustration 105
(11) Bolts
(12) Generator supports
11. Install all bolts (11) which fasten generator

supports (12) to the base. Do not tighten. Align
the generator to the engine. Go to the following
alignment procedure which corresponds to the
particular generator set.
56
Generator Sets With 3500 Engine Family

Table 25
TABLE FOR RECORDING MEASUREMENTS AND CALCULATIONS THAT ARE NECESSARY FOR THE INSTALLATION
AND THE ALIGNMENT OF GENERATOR SETS WITH SINGLE BEARING GENERATORS
Line Step Description Value
A Step 2 Crankshaft End Play
B Step 2 A/2=
C Step 3 Flywheel Housing Surface
D Step 3 Flywheel Pilot Surface
E Step 3 C-D=
F Step 5 Rotor End Play
G Step 5 F/2=
H Step 6 End Ring
I Step 6 Drive Coupling
J Step 6 I-H=
K Step 7 Average Thickness of Plates
L Step 8 Shim Gap
J−B−E−G−K=
M Step 8 Total Number of Shims
L ÷ 0.8 mm (0.032 inch) = (1)
N Step 14 Crankshaft End Play After Assembly
P Step 14 Heat sink End Play After Assembly
Q Step 14 Compare “N” to “A”.
If “N” is greater than “A” or equal to “A”, the installation
is finished.
If “N” is less than “A”, repeat the installation. Check for
calculation errors and check for measurement errors.
(1) Round this value up to the nearest whole number.
Table 26
PARTS NEEDED
Part Number Part Quantity
5N-4479 Shim 6
5N-4478 Plate Assembly 1
Table 27
TOOLS NEEDED
g00616707
Illustration 106
(1) Flywheel Pilot Bore
(2) Surface
8S-2328 Dial Indicator 1
Group
Disengage the generator from the engine. Perform

the following procedure.
57
1. Remove all dirt, burrs and paint from the contact

surfaces of the generator supports and the base.
Remove the protection material (compound)
from flywheel pilot bore (1) and from surface
(2). There should be no protection material that
makes contact with the coupling. All contact
surfaces of the engine, the coupling and the
generator must be completely clean.
g00617579
Illustration 107
(1) Dial indicator
2. Remove two of the engine side covers. Use a bar

to rotate the crankshaft. Rotate the crankshaft
until one of the crankshaft’s throw cheeks is
perpendicular to the side cover’s opening. Place
a dial indicator on the perpendicular surface
of the throw. Place a bar between the engine
block and the crankshaft throw. Use the bar to
push the crankshaft toward the flywheel in order
to remove all end play. Zero the dial indicator.
Turn the crankshaft to the most forward position.
The amount of crankshaft end play that is
shown on the dial indicator should be 0.178 mm
(0.0070 inch) to 0.635 mm (0.0250 inch).
a. Record the measured value of crankshaft end

play on “Line A” of Table 25.
b. Divide the value of “Line A” by two. Record

this value on “Line B” of Table 25 (A / 2 = B).
58
g00617602
Illustration 108
(1) Straight edge (2) Flywheel (3) Flywheel housing
3. Place the engine crankshaft at the extreme

forward position. Position straight edge (1) across
the face of flywheel (2). See Illustration 108.
a. Measure the distance between the top of

straight edge (1) and flywheel housing (3)
(mounting surface “C”). Record the value on
“Line C” of Table 25.
b. Measure the distance between the top of

straight edge (1) and Flywheel (2) (pilot
surface (D)). Record the value on “Line D”
of Table 25.
c. Subtract “Line D” from “Line C”. Record the g00617609

value on “Line E” of Table 25 (C - D = E). Illustration 109
(5) Coupling bolts
(6) Flex plates
59
4. Remove coupling bolts (5) and washers. Remove

flex plates (6), shims, and the exhaust fan. See
Illustration 109. Attach a hoist to the rotor shaft
and lift the rotor assembly. Locate the rotor so
that the air space between the rotor and the
stator is equal. Move the rotor to the rearmost
position.
g00617618
Illustration 110
5. Place a dial indicator on the vertical surface of

the heat sink assembly. The heat sink assembly
is located at the rear of the generator’s rotor
shaft. See Illustration 110. The dial indicator’s
plunger should be preloaded so that the forward
movement of the rotor can be measured.
Use the generator drive coupler to move the
rotor forward. The amount of rotor end play
that is shown on the dial indicator should be
approximately 3.81 mm (0.150 inch) to 7.62 mm
(0.300 inch).
a. Record the measured value of rotor end play

on “Line F” of Table 25.
b. Divide the value of “Line F” by two. Record

this value on “Line G” of Table 25 (F / 2 = G).
60
g00617620
Illustration 111
(7) Straight edge (8) End ring (9) Drive coupling
6. Move the rotor assembly to the rearmost position. 7. Take a standard set of seventeen 5N-4478
Before proceeding, ensure that the air gap is flex plates. Bolt the plates together by using
equal between the rotor assembly and the stator. the flywheel mounting holes. The bolts should
Position straight edge (7) across the diameter of be tight, but not tightened to the final torque.
end ring (8). See Illustration 111. Measure the thickness of the plates in two
locations along the border.
a. Measure the distance from the top of straight
edge (7) to the mounting surface (H) of end a. Calculate the average of the two
ring (8). Record this value on “Line H” of measurements. Record this value on “Line K”
Table 25. of Table 25.
b. Measure the distance from the top of straight 8. In order to determine the number of shims that
edge (7) to the mounting surface (I) of drive are required to provide proper axial alignment,
coupling (9). Record the value on “Line I” of perform the calculation that is shown on “Line L”
Table 25. of Table 25 (J - B - E - G - K = L). Record this
value on “Line L” of Table 25.
c. Subtract “Line H” from “Line I”. Record this
value on “Line J” of Table 25 (I - H = J). a. Divide the value of “Line L” by 0.8 mm
(0.032 inch). Record this new value on “Line
Note: Attachment of the straight edge (ferrous M” of Table 25. The value that is shown on
material) can be accomplished by using two “Line M” is the total number of shims. This
magnetic bases from the dial indicator. value should be rounded up to the nearest
whole number.
61
9. Put the coupling plate assembly in position at

the flywheel bore in order to check for clearance.
There must be clearance between the coupling
plate assembly’s outside diameter and the
flywheel bore’s inside diameter.
g00617618
Illustration 114
12. Place the crankshaft and the generator rotor in

the respective rearmost positions. Place a dial
indicator on the vertical surface of the heat sink
Illustration 112
g00617609 assembly. The heat sink assembly is located at
(5) Coupling bolts
the rear of the generator rotor shaft. The dial
(6) Coupling plate assembly indicator’s plunger should be preloaded so
that the forward movement of the rotor can be
measured. Push the generator forward to the
NOTICE midpoint of end play (0.5 mm (0.02 inch)).
Do not run the generator set unless the plate assembly
has the correct clearance. If the plate assembly does
not have the correct clearance, damage can occur to
the engine and/or generator.
10. Place the total number of shims onto the

drive coupling. The total number of shims was
calculated on “Line M” of Table 25. Install
coupling plate assembly (6) and bolts (5).
Tighten the bolts to the proper torque.
g00617698
Illustration 115
(11) Fan bolts
13. Install fan bolts (11) into the flywheel. Tighten

the fan bolts to standard torque.
g00617679
Illustration 113
(10) Bolts
11. Install guide bolts in the flywheel. Guide bolts will

assist in attaching the generator to the engine.
Put the generator in position on the engine.
Install bolts (10) which fasten the generator
housing to the flywheel housing. Tighten bolts
(10) to the standard torque.
g00617579
Illustration 116
62
14. Place a dial indicator on the vertical surface of Align Generator Sets With No Supports
the crankshaft throw cheek. Place another dial At The Flywheel Housing
indicator on the vertical surface of the heat sink
assembly. Refer to Step 12. Push the crankshaft
forward in order to determine the amount of end
play. The amount of crankshaft end play that is
shown on the dial indicator should be 0.178 mm
(0.0070 inch) to 0.635 mm (0.0250 inch). The
amount of heat sink end play that is shown on the
dial indicator should be 0.076 mm (0.0030 inch)
to 0.635 mm (0.0250 inch).
a. After assembly is complete, measure the

crankshaft end play. Record this value on
“Line N” of Table 25.
b. After assembly is complete, measure the

heat sink end play. Record this value on “Line Illustration 117 g00616479
P” of Table 25. A Generator set with no supports at the flywheel housing
(1) Engine support
Note: If the value of “Line N” or the value of “Line (2) Base
P” is less than the value of “Line A”, disassemble (3) Generator support
the generator. Check the coupling plate assembly
for bowing. If bowing is present, replace the 1. If the base (2) of the electric set is fastened to
coupling plate assembly. Check the calculations a foundation, loosen all the bolts that connect
and measurements of these procedures for errors. the base to the foundation. Loosen all bolts that
fasten the generator supports (3) and engine
15. Install the generator and again repeat Step 12 supports (1) to the base (2).
through Step 14. After the correct amount of
shims have been installed and all measurements 2. Ensure that there is clearance between the
are within limits, proceed with installation. Align bolts and the bolt holes in the base, the engine
the generator to the engine. Go to the following supports and the generator supports at all
alignment procedure which corresponds to the locations.
particular generator set.
3. Check the clearance between the base and
i01158999
the foundation at all mounting locations. Shims
should be used in order to prevent the deflection
Generator - Align of the base as the bolts that connect the base
to the foundation are tightened. When there is
SMCS Code: 4450-024 no deflection of the base, tighten all bolts that
connect the base to the foundation to the final
torque.
Generator Alignment
Note: For the alignment procedure for two-bearing
close coupled generators, see Special Instruction,
SEHS7073, “Alignment Of Two Bearing Generators”.
Note: A specific alignment procedure is not required

for generators that are soft mounted.
g00616477
Illustration 118
(1) Base
(2) Generator support
(3) Shims
63
4. Check the clearance between the base (1) and

the engine. Check the clearance between the
base (1) and the engine supports. Check the
clearance between the base and the generator
supports (2). Check the clearance over the
entire length of the supports. This is especially
important on generators with long supports (2),
since some of the surfaces may not be square
or parallel. Shims should be used in order to
prevent the deflection of the supports as the
bolts are tightened. After all the necessary shims
have been installed, finish tightening all mounting
bolts to the final torque.
Align Generator Sets With Supports At Illustration 120 g00295995

The Flywheel Housing (2) Bolts
g00616490 g00295996
Generator Set With Supports At The Flywheel Housing (3) Support
(1) Base (4) Bolt
(5) Shims
1. If base (1) of the electric set is fastened to a
foundation, loosen all bolts that connect the base 4. While the generator is supported by a crane,
to the foundation. Loosen all bolts that fasten loosen all bolts (2) that fasten the generator to
the engine supports and generator supports to the flywheel housing. Tighten alternate bolts to
the base. the final torque.
2. Ensure that there is enough clearance between 5. Check the clearance between the base and
the bolts and the bolt holes in the base, engine the engine and generator supports at all four
supports and generator supports at all locations. locations. Check the clearance over the entire
length of the supports. This is especially
3. Check the clearance between the base and important on generators with long supports (3).
the foundation at all mounting locations. Shims Shims (5) should be installed until all of the
should be used in order to prevent the deflection mounting surfaces are flat and parallel.
of the base as the bolts that connect the base
to the foundation are tightened. When there is 6. Tighten all bolts that fasten the engine supports
no deflection in the base, tighten all bolts that and the generator supports to the base to half of
connect the base to the foundation to the final the final torque. Loosen all bolts (2) that fasten
torque. the generator to the flywheel housing. Measure
the gap between the generator and the flywheel
housing. Visually ensure that the bolts (2) are
centered in the clearance holes.
64
9. Install a dial indicator on the base (1) with the

indicator tip next to a support mounting bolt (3).
Put the indicator tip on the support (2). Check
the indicator while you are tightening the bolt to
the final torque. If the indicator moves more than
0.13 mm (0.005 inch), the thickness of the shim
is incorrect under that bolt. Install the necessary
amount of shims. Repeat this procedure until
all the mounting bolts for the engine support
and the mounting bolts for the generator support
have been tightened to the final torque and the
support deflection is within the specification.
i01158402
g00295997
Illustration 122
Rotor - Remove and Install
7. The gaps at locations (E), (G), (F), and (H)
should be more than 0.03 mm (0.0012 inch) SMCS Code: 4457-010
and less than 0.13 mm (0.005 inch). If the gaps
at locations (E) and (G) are not correct, adjust Removal Procedure
the number of shims under each generator
support. If the gaps at locations (F) and (H) are Start By:
not correct, loosen the bolts in the generator
supports. Move the rear of the generator to the a. Remove the generator. Refer to Disassembly and
right or left accordingly. Assembly, “Generator - Remove”.
8. After a correction has been made to the b. Remove the exciter field and remove the exciter
thickness in the shims, tighten the generator armature. Refer to Disassembly and Assembly,
support’s bolts to half of the final torque 450 N·m “Exciter - Remove and Install”.
(332.0 lb ft). Check the gap at locations (E), (G),
(F), and (H). Repeat this procedure until the gap
measurements are 0.13 mm (0.005 inch) or less.
Begin with Step 6.
g00615990
Illustration 124
(1) Bolts
(2) Coupling plate
g00616519 1. Remove bolts (1) which fasten coupling plate

Illustration 123
(1) Base (2) to the rotor. Remove the coupling plate. The
(2) Support coupling plate assembly can be a single solid
(3) Bolt plate or the coupling plate assembly can be
numerous flexible plates.
65
3. Attach straps or chains to the drive end of

the generator housing. With a hoist, raise the
generator until the generator is in a vertical
position. Ensure that the drive end is oriented
upward.
g00615994
Illustration 125
(3) Shims
(4) Fan
2. Remove shims (3) from the rotor shaft. Remove

fan (4) from the generator housing. Illustration 128
g00616056
400 frame generator

Note: On 3406E Generator Sets, do not remove the
The strap is used to secure generator leads.
fan at this point.
g00616057
g00616040 Illustration 129
Illustration 126
800 frame generator
400 Frame Generator
4. Align the blocks with the generator housing’s

outside diameter. Lower the generator onto the
blocks.
5. There is a generator bearing on the exciter end

of the rotor shaft. This bearing is retained in the
generator end housing. The bearing is retained
in the generator end housing by a bearing cap
or the bearing is retained in the generator end
housing by retainer bars.
When the generator end housing is equipped

with retaining bars, remove the four bolts that
fasten the retaining bars to the generator end
Illustration 127 g00616013 housing. Remove the retaining bars.
800 Frame Generator
66

with a bearing cap, remove the necessary bolts
that fasten the bearing cap to the generator end
housing. Pry the bearing cap out of the generator
end housing. The bearing cap remains with the
rotor shaft. If a bearing lube line is attached to
the bearing cap, remove the lube line.
g00616101
Illustration 132
400 Frame Single Bearing Generator
(8) Protective strip
(9) Drive coupling
g00624626
Illustration 130
(5) Bolts
6. On 3406E generator sets, the drive end housing

must be removed. Attach a hoist to the drive end
housing. Remove the bolts (5) that attach the
drive end housing to the generator. Remove the
drive end housing.
g00616108
Illustration 133
800 Frame Two-Bearing Generator
(9) Drive coupling
NOTICE
During removal of the generator, the rotor assembly
must not contact the stator assembly. If the rotor as-
sembly contacts the stator assembly, the windings can
be damaged.
g00616086
Illustration 131 8. Put protective strips (8) of cardboard, plastic or
800 Frame Two-Bearing Generator curved sheet metal between the rotor assembly
(6) Bolts and the stator assembly. The pieces should be
(7) Drive end housing as long as the rotor assembly. These pieces
protect the rotor and these pieces protect the
7. For two-bearing generators, bolts (6) which stator from damage during rotor removal.
fasten drive end housing (7) to the generator
must be removed. The drive end housing For two-bearing generators, put a mark on drive
remains with the rotor shaft. Remove the bolts. end housing (7) and the generator housing. This
will ensure proper alignment during installation.
9. Attach a hoist to drive coupling (8). Remove the

rotor assembly from the stator assembly.
67
Installation Procedure
Start By:
a. Place the generator in a vertical position. Ensure

that the drive end is oriented upward.
g00616086
Illustration 135
(6) Bolts
(7) Drive end housing
5. On a two-bearing generator, tighten the bolts

(6) that attach the drive end housing (7) to the
Illustration 134
g00616101 generator.
400 Frame Single Bearing Generator
(9) Drive coupling
1. Put protective strips (8) of cardboard, plastic or

curved sheet metal between the rotor assembly
and the stator assembly. The pieces should be
as long as the rotor assembly. During installation
of the rotor, these pieces protect the rotor from
damage. These pieces also protect the stator
from damage.
2. Attach a hoist to drive coupling (9). Lower the

rotor assembly into the stator assembly.
g00624626
Illustration 136
3. For two-bearing generators, the drive end
housing is attached to the rotor shaft. When (5) Bolts
the rotor was removed from the generator, an
alignment mark was made on the drive end 6. On a 3406E generator set, install the drive end
housing and the generator housing. Align these housing. Tighten bolts (5).
marks. Start the bolts that attach the drive end
housing to the generator. Do not tighten the bolts.
4. There is a generator bearing on the exciter end

of the rotor shaft. This bearing is retained in the
generator end housing. The bearing is retained
in the generator end housing by a bearing cap
or the bearing is retained in the generator end
housing by retaining bars.

with retaining bars, install the four bolts that
housing.
g00615994
Illustration 137
with a bearing cap, install the necessary bolts
that fasten the bearing cap to the generator end 7. Place fan (4) in the drive end housing.
housing. If a bearing lube line is attached to the
bearing cap, install the lube line. 8. Install shims (3) on the rotor shaft.
68
g00615990 g00615777
9. Install coupling plate (2) on the rotor. Tighten
bolts (1). 1. Put protective strips (1) of cardboard, plastic or
curved sheet metal between the rotor assembly
and the stator assembly. The pieces should be
i01731574
as long as the rotor assembly. During removal of
Bearing - Remove and Install the end housing, these pieces protect the rotor
and these pieces protect the stator from damage.
SMCS Code: 4471-010
2. The generator bearing is retained in the generator
end housing. On the inside of the generator end
Removal Procedure housing, a bearing cap or retaining bars are
used to retain the bearing.
Start By:
a. Remove the exciter field and remove the exciter

armature. Refer to Disassembly and Assembly,
“Exciter - Remove and Install” and Disassembly
and Assembly, “Rotor - Remove and Install”.
Table 28
TOOLS NEEDED
1H-3107 Push-Puller 1
1H-3108 Push-Puller Leg 2
1H-3110 Bearing Pulling 1
Attachment g00615790
Illustration 140
Retaining Bar
(2) Retaining bar
3. If the generator end housing is equipped with

retaining bars (2), remove the four bolts that
housing. Remove the retaining bars.
69
g00615797 g00615809
Bearing Cap (6) Tooling
(3) Bearing Cap
6. Attach tooling (6). Remove the bearing.
bearing cap (3), remove the necessary bolts Two-Bearing Generator
which fasten the bearing cap to the generator
end housing. Pry the bearing cap out of the Table 29
generator end housing. The bearing cap remains TOOLS NEEDED
with the rotor shaft. If a bearing lube line is
attached to the bearing cap, remove the lube Part Number Tool Quantity
line. 1U-6415 Puller Group (40 ton) 1
Note: On two-bearing generators, there is a bearing

on each end of the generator. To remove the bearing
that is located at the drive end of the generator, use
the following procedure.
For removal of the bearing at the drive end of the

generator, begin by removing the drive coupling.
Refer to Disassembly and Assembly, “Coupling -
Remove”.
g00615803
Illustration 142
(4) End housing
(5) Bolts
Note: The weight of end housing (4) varies with the

size of the generator. Larger end housings require
the use of a hoist.
5. Attach a hoist to end housing (4). Remove bolts

(5) that fasten end housing (4) to the generator.
Use a pry bar to separate the end housing
g00615814
from the generator. Some end housings have Illustration 144
provisions which allow the use of forcing screws. (1) Bolts
Lift the end housing from the generator and
remove the end housing from the generator. 1. The generator bearing is retained in the generator
end housing. On the inside of the generator end
housing, a bearing cap retains the bearing.
70
Remove bolts (1) which fasten the bearing cap to

the generator end housing. Pry the bearing cap
out of the generator end housing. The bearing
cap remains with the rotor shaft. If a bearing
lube line is attached to the bearing cap, remove
the lube line.
g00615824
Illustration 147
Replaceable bearing wear sleeve (inside view of end housing)
(5) Bearing wear sleeve
Some end housings have a bearing wear sleeve

g00615816
(5) which is replaceable.
Illustration 145
(2) End Housing
(3) Bolts Installation Procedure
2. Attach a hoist to end housing (2). Remove To install the bearing that is located at the exciter
bolts (3) which fasten end housing (2) to the end of the generator, use the following procedure.
generator. Use a pry bar to separate the end
housing from the generator. Some end housings 1. Heat the bearing to 149 C (300.2 F).
have provisions which allow the use of forcing
screws. Lift the end housing from the generator 2. While the bearing is heated to 149 C (300.2 F),
and remove the end housing from the generator. place the bearing inside the end housing.

a bearing cap, attach bearing cap to the end
housing. Install bolts.
4. If equipped, attach bearing lube line to the

bearing cap.

retaining bars, attach the retaining bars to the
end housing. Install bolts.
Two-Bearing Generator
Note: On two-bearing generators, there is a bearing
g00615820
Illustration 146 on each end of the generator. To install the bearing
(4) Removal Tool 1U-6415 on the drive end of the generator, use the following
procedure.
3. Attach tooling (4). Remove the bearing.
1. Heat the bearing to 149 C (300.2 F).
2. While the bearing is heated to 149 C (300.2 F),

place the bearing inside the generator end
housing.
3. Attach a hoist to the generator end housing.

Attach the generator end housing to the
generator. Install bolts.
71
4. Attach bearing cap to the end housing. Install

bolts.
5. If equipped, attach bearing lube line to bearing

cap.
i01157853
Coupling - Remove
SMCS Code: 4456-011
Removal Procedure
g00615513
Start By: Illustration 149
a. Remove the generator. See the topic Disassembly 2. Slide the coupling on the rotor until the stop
and Assembly, “Generator - Remove”. fixture contacts the end of the rotor shaft.
Table 30
TOOLS NEEDED
Tool Quantity
Acetylene Torch with a Rosebud Tip 2
Heat Resistant Gloves 1
g00615518
Illustration 150
3. Remove the stop fixture from the coupling.
i01602306
Coupling - Install
g00615745
Illustration 148 SMCS Code: 4456-012
1. Simultaneously, heat the two opposite ends of Installation Procedure

the drive coupling. Use two acetylene torches
that are equipped with rosebud tips. This method Table 31
will quickly heat the coupling. Heat the coupling
for three to five minutes. Do not overheat the TOOLS NEEDED
coupling. Tool Quantity
Stop Fixture. Refer to Illustration 151. 1
Heat Resistant Gloves 1
Always wear protective gloves when handling
parts that have been heated.
72
g00615434 g00615513
Stop Fixture Fabrication
(A) 114.3 mm (4.50 inch) 4. Slide the coupling on the rotor shaft. Continue to
(B) 19.7 mm (0.78 inch) slide the coupling until the stop fixture contacts
(C) 45.5 mm (1.79 inch) (for SR4B only) the rotor shaft.
(C) 39.4 mm (1.55 inch) (for SR4 only)
(D) 50.8 mm (2.00 inch)
(E) 12.7 mm (0.50 inch)
(F) 19.1 mm (0.75 inch)
(G) 50.8 mm (2.00 inch)
1. Evenly heat the coupling to 315 C (599.0 F).

An oven is the preferred method for heating the
coupling.
Always wear protective gloves when handling

parts that have been heated.
g00615518
Illustration 154
2. Place the coupling on a work bench.
5. Remove the stop fixture from the coupling.
g00615500
Illustration 152
A Coupling with a stop fixture attached.
3. Attach the stop fixture to the coupling.

73
Index Section
Index
B I
Bearing - Remove and Install ................................ 68 Important Safety Information ................................... 2

Installation Procedure ........................................ 70 Insulation - Test ..................................................... 36
Removal Procedure ........................................... 68 Exciter Armature (Rotor L2)............................... 37
Exciter Field (Stator L1) ..................................... 37
Main Armature (Stator L4) ................................. 37
C Pilot Exciter Armature L5 ................................... 37
Component Descriptions ................................... 5, 10

Exciter................................................................ 11 L
Main Field (Rotor) .............................................. 11
Pilot Exciter ........................................................ 11 Lead Connections.................................................. 20
Rotating Field Assembly (RFA) .......................... 10 Four Lead Wye Connection ............................... 21
Rotating Rectifier Blocks.................................... 11 Six Lead Delta Connection ................................ 23
Coupling - Install.................................................... 71 Six Lead Wye Connection.................................. 21
Installation Procedure ........................................ 71 Ten Lead Wye Connection (High Voltage) ......... 21
Coupling - Remove................................................ 71 Ten Lead Wye Connection (Low Voltage) .......... 22
Removal Procedure ........................................... 71 Twelve Lead Delta Connection .......................... 24
Twelve Lead Wye Connection (High Voltage) .... 22
Twelve Lead Wye Connection (Low Voltage) ..... 23
D Leads - Connect .................................................... 40
Generator Lead To Other Lead .......................... 40
Disassembly and Assembly Section...................... 44 Generator Leads To Terminal Strips .................. 40
E R
Exciter - Remove and Install.................................. 44 Resistor - Test........................................................ 38

Installation Procedure ........................................ 47 Rotating Rectifier - Test ......................................... 32
Removal Procedure ........................................... 44 Six-Diode Rectifier Block ................................... 32
Exciter Field - Flash............................................... 41 Three-Diode Rectifier Block ............................... 33
Dynamic Flashing (Running Engine) ................. 42 Two-Diode Rectifier Block .................................. 34
Static Flashing (Stopped Engine) ...................... 42 Rotor - Remove and Install.................................... 64
Installation Procedure ........................................ 67
Removal Procedure ........................................... 64
G
General Information........................................... 4, 28 S
Generator - Align ................................................... 62
Generator Alignment.......................................... 62 Service Tools ......................................................... 28
Generator - Dry ..................................................... 38 Systems Operation Section ..................................... 4
Drying Methods.................................................. 38
Generator - Install.................................................. 53
Installation Procedure ........................................ 53 T
Generator - Remove .............................................. 49
Removal Procedure ........................................... 49 Table of Contents..................................................... 3
Generator Operation.............................................. 12 Testing and Adjusting ............................................ 28
Generator Circuit Protection .............................. 19 Testing and Adjusting Section ............................... 28
Permanent Magnet Pilot Excited (PMPE) Troubleshooting ..................................................... 29
Generator ......................................................... 13 Problem List ....................................................... 30
Rectifier Circuits................................................. 15 Visual Checks .................................................... 30
Self-Excited (SE) Generators............................. 14
Space Heaters ................................................... 20
Generator Set - Test .............................................. 30 V
Glossary ................................................................ 24
Varistor - Test......................................................... 32
74
Index Section
Winding - Test........................................................ 35
75
Index Section
©2002 Caterpillar
All Rights Reserved Printed in U.S.A.

Manual Generador SR4 B SENR5359-05

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Manual Generador SR4 B SENR5359-05

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SENR5359-05

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Testing and Adjusting Section

Disassembly and Assembly Section

Systems Operation Section

• three-phase alternating current

The SR4B generator is a self-ventilated generator.

All SR4B generators have the same basic design.

• Power for the exciter field is provided by either

• The location of the bearing can be inboard or

• On PMPE generators, the pilot exciter can be

Note: Some larger generators have two bearings.

Rotating Field Assembly (RFA)

The RFA components attach to rotor shaft (5), which

Main Field (Rotor) Pilot Exciter

Exciter Rotating Rectifier Blocks

An engine supplies the power in order to turn rotor

When the engine starts turning the Rotating Field

Direct current now flows to exciter field (L1) which

The amount of current which flows through the

Note: For more information on voltage regulation,

Self-excited generators are an option. The standard

When the voltage regulator senses a decrease in Rectifier Circuits

Diodes “CR1” through “CR6” are contained in

There are three types of rotating rectifier blocks:

Two-diode rectifier block – The two-diode rectifier

Three-diode rectifier block – The three-diode rectifier

Six-diode rectifier block – The six-diode rectifier

Rectifying the current creates heat. The rotating

Two-Diode Rectifier Block

Three identical two-diode rectifier blocks (3) are

• “CR1” and “CR4”

The two-diode rectifier blocks (3) are mounted to

Three-Diode Rectifier Block

In order to form a bridge rectifier circuit, two similar

Three-diode rectifier blocks must be wired correctly.

The positive rectifier block (1) and the negative

Six-Diode Rectifier Block

The six-diode rectifier block contains the six diodes

On inboard bearing type generators, the six-diode

Generator Circuit Protection

Varistor (CR7) protects the following diodes

Note: Some generators are provided with another

The voltage regulator and related components also

All voltage regulators have excessive current

An external source is required to operate the space

The Wye configurations and the Delta configurations

The space heater for small frame generators is

Four Lead Wye Connection Table 2

Ten Lead Wye Connection (High

Six Lead Wye Connection

Table 3 Twelve Lead Wye Connection (High

Ten Lead Wye Connection (Low

Twelve Lead Wye Connection (Low Six Lead Delta Connection

Table 6 SIX LEAD DELTA CONNECTIONS

Depending on the connections that are made

Actuate – Actuation relates to putting something

Anode – An anode is the positive end of a diode or

Full-Wave Rectifier – A full-wave rectifier changes Module – A module is an assembly of electronic

Phase Winding – A phase winding is a group of Semiconductor – A semiconductor is a component

Voltage Gain Resistor – A voltage gain resistor is a